4 - Speed automatic gearbox 001 — 3rd and 4th gear clutch -K3-: 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. Press the plunger cover carefully downward until the sealing ring can be assembled.
2. Assemble the external discs (4) and the internal discs (3) in the clutch bellhousing.
3. Place the bearing disc (2) 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. Place the clutch -K3- over the transmission case cover and press it downward.
16. Blow compressed air into the pressure channel (arrow).
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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