Dismantling and assembling 1st to 3rd gear clutch -K1- — VW

VW
Polo
2002
Power transmission
4-speed automatic transmission 001
Edition
10.2004
Dismantling and assembling 1
st
to 3
rd
gear clutch -K1-
Functional check of clutch
Fig.
.
Circlip
Lever out with screwdriver
Thrust plate
Installing
Fig.
“
Installing outer and inner plates
”
Determining thickness
Fig.
“
Determining thickness for the pressure plate
”
Inner plate
Installing
Fig.
“
Installing outer and inner plates
”
Quantity
Chapter
Outer plate
Installing
Fig.
“
Installing outer and inner plates
”
Quantity
Chapter
Dished washer
Installing
Fig.
“
Installing outer and inner plates
”
Securing ring
Removing and installing
Fig.
“
Removing and installing circlip
”
Oil seal
Always renew
Piston cap
Moisten sealing ring with ATF before installing
Spring
Seat between piston and piston cap
Oil seal
Always renew
Sealing lip faces to clutch housing
Oil seal
Always replace
Piston
Spare part is allocated according to gearbox code letters
Installing
Fig.
“
Functional check of clutch
”
Clutch housing with turbine shaft
Piston ring
Check that it is correctly located
Do not overstretch
Removing and installing circlip
Press piston cap and spring down far enough for the circlip
arrow
to be inserted in the groove.
Installing outer and inner plates
Convex side of dished washer (small diameter) faces to clutch housing.
Place outer plates
2
and inner plates
4
on the dished washer
3
.
Place pressure plate
5
on the last inner plate.
Fit circlip
1
in the groove in the clutch housing.
Determining thickness for the pressure plate
Measure play between pressure plate and circlip using a feeler gauge
A
.
Component
Installed dimension
Wear limit
Clutch K1
0.45 ... 0.85 mm
1.05 mm
If the wear limit is reached on a used clutch, the plates must be replaced and the thickness for a new pressure plate must be calculated.
Allocate plates and pressure plate according to gearbox code letters.
Functional check of clutch
Before installing the piston moisten sealing lip and sealing rings with ATF.
Turn piston slightly when installing.
It must be possible to turn the piston by hand in both directions
arrows
after it has been installed into clutches or brakes.
Note
If this is not the case, the sealing lips or sealing rings may catch or become damaged.
If this defect occurs, remove piston again.
Check sealing lips or sealing rings for damage, renew if necessary.
Install piston again and check.
Blow compressed air into the pressure channel
arrow
Keep the drilling on the opposite side closed.
The clutch piston must press the plates together.
Allow compressed air to escape. The set of plates must return to its rest position.