4 - Speed automatic gearbox 001 — 1st to 3rd gear clutch -K1-: disassemble and assemble — VW

🧭 Before you start

Fits: platform code POLO

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• If the wearing limit is reached with the clutch used, the discs must be changed and a new, proper bearing disc must be selected.
• Once the plunger is assembled in the clutches or the brakes, it must be able to be manually turned easily in both directions (arrows).
• The clutch plunger must compress the disc pack.
• Let compressed air bleed. The disc pack must return to its resting position

📋 Procedure

1. Push the plunger cover with the spring downward until it is possible to keep the sealing ring in the notch (arrow).
2. Place the external discs (2) and the internal discs (4) over the dish spring (3).
3. Place the bearing disc (5) over the last internal disc.
4. Put the sealing ring (1) in the clutch bellhousing notch.
5. With a gauge "A", measure the oscillation between the bearing disc and the sealing ring.

6. If the wearing limit is reached with the clutch used, the discs must be changed and a new, proper bearing disc must be selected.
7. Allocate the discs and the bearing disc due to the distinctive letters in the transmission.
8. Before assembling the plunger, apply ATF over the sealing lips and the retainers.
9. Slightly turn the plunger when assembling it
10. Once the plunger is assembled in the clutches or the brakes, it must be able to be manually turned easily in both directions (arrows).
11. If not, the sealing lips or the retainers may not be completely inserted or are damaged.
12. Disassemble the plunger if such abnormality occurs.
13. Check if the sealing lips or the retainers are damaged and change them if necessary
14. Assemble the plunger and review it again.
15. Blow compressed air into the pressure channel (arrow).
16. Plug the hole in the opposite side.
17. The clutch plunger must compress the disc pack.
18. Let compressed air bleed. The disc pack must return to its resting position

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