Automatic gearbox 001 — Dismantling and assembling 1st to 3rd gear clutch K1 — VW

🧭 Before you start

Fits: VW Polo 9N (2001–2009)

• Special tools named: feeler gauge
• Renewed: as necessary

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• If wear limit has been reached on a used clutch, the plates must be replaced and the thickness for a new pressure plate must be calculated.
• Before installing a piston, moisten sealing lips and seals with ATF.
• When a piston is installed in a clutch or brake, it must be possible to move it by hand without friction in both direction (arrows).
• The clutch piston must press the plates together.
• Allow compressed air to escape. The set of plates must return to its rest position.

📋 Procedure

1. Press piston cap with spring down far enough for retaining ring (arrow) to be inserted in groove.
2. Set outer plates (2) and inner plates (4) on dished washer (3).
3. Place pressure plate (5) on the last inner plate.
4. Insert retaining ring (1) in groove in clutch housing.
5. Measure play between pressure plate and retaining ring using a feeler gauge (A).

6. If wear limit has been reached on a used clutch, the plates must be replaced and the thickness for a new pressure plate must be calculated.
7. Allocate plates and pressure plate according to gearbox code.
8. Before installing a piston, moisten sealing lips and seals with ATF.
9. Turn piston slightly when installing.
10. When a piston is installed in a clutch or brake, it must be possible to move it by hand without friction in both direction (arrows).
11. If this problem occurs, remove the piston again.
12. Check sealing lips and sealing rings for damage and renew as necessary.
13. Reinstall piston and check again.
14. Blow compressed air into pressure channel (arrow) with a compressed air gun.
15. Hold hole on opposite side closed.
16. The clutch piston must press the plates together.
17. Allow compressed air to escape. The set of plates must return to its rest position.

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