Content .. 117 118 119 120 ..

Volkswagen 01M Transmission. Manual - part 119

Continued on Page 107

106

Technical Service Information

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03C2T02168

300 035H

09G

1004

Figure 177

426

THIS OPENING
TOWARDS THE

TRANSFER GEAR

ENSURE THESE LUGS

ARE ENGAGED IN

THESE SLOTS

427

426 B1 CLUTCH HOUSING RETAINING SNAP RING.
427 B1 CLUTCH HOUSING.

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1004

Figure 178

424

425

422

421

423

421 B1 CLUTCH "BELLVILLE" CUSHION SPRING.
422 B1 CLUTCH BACKING PLATE, STAMP 10, 2.52MM (.099") THICK.
422 B1 CLUTCH BACKING PLATE, STAMP 3, 2.4MM (.095") THICK.
423 B1 CLUTCH FRICTION PLATES (QTY MAY VARY).
424 B1 CLUTCH STEEL PLATES, 1.8MM (.071") (QTY MAY VARY).
425 B1 CLUTCH "STEPPED" PRESSURE PLATE, 2.9MM (.114") THICK.

TRANSAXLE FINAL ASSEMBLY (CONT'D)

26. Install the B1 clutch housing with the opening
towards the transfer driven gear, as shown in
Figure 177, and insure lugs are engaged in slots
in the center support.
27. Install the B1 clutch housing retaining snap ring
with opening towards the transfer gear, as shown
in Figure 177, and ensure it is fully seated in the
center support.
Note: This snap ring is identified by two small
"turn-outs" at the snap ring ends, as shown in
Figure 177.

ROUNDED EDGE

FACING DOWN

ID STAMP

Continued on Page 108

107

Technical Service Information

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03C2T02168

300 035H

09G

1004

Figure 179

131

134

133

132

REAR VIEW

120 NUMBER 5 THRUST BEARING RACE.
131 K1 CLUTCH HOUSING ASSEMBLY.
132 NUMBER 6 THRUST BEARING.
133 NUMBER 6 THRUST BEARING RACE.
134 K3 CLUTCH HOUSING DRIVE HUB.

28. Install the B1 clutch "stepped" pressure plate, as
shown in Figure 178, with "step" facing down.
29. Install B1 clutch pack beginning with a friction
plate onto the pressure plate and alternating with
a steel plate, as shown in Figure 178, until you
have installed the proper quantity, as the quantity
may vary.
Note: All friction plates should be soaked in
proper fluid for 30 minutes before installing.
30. Install the B1 clutch backing plate on top of the
last friction, as shown in Figure 178, with the
rounded edge facing the friction.
Note: Notice the number stamped on top side
of backing plate, which is an indicator that it
is selective, but no selectives available as yet.
31. Install the B1 clutch "bellville" cushion plate in
the direction shown in Figure 178.
Note: There is no backing plate snap ring for
the B1 clutch pack. We will check B1 clutch
clearance before installing oil pump, as the
apply piston is in the oil pump assembly. The
apply piston caged return spring assembly sits
between the piston and cushion plate, retaining
the B1 clutch pack.
32. Install K3 clutch housing drive hub, as shown in
Figure 179, and engage on splines of sun gear.
33. Install the number 6 thrust bearing race into the
drive hub, as shown in Figure 179.
34. Install the number 6 thrust bearing with needles
facing down, as shown in Figure 179.
35. Install completed K1 clutch housing, as shown
in Figure 179.
36. Ensure that number 5 thrust bearing race is still
in place on K1 clutch housing, as shown in
Figure 179.

TRANSAXLE FINAL ASSEMBLY (CONT'D)

120

40. Install the B1 clutch apply ring and return spring
assembly, as shown in Figure 181.
Note: Return spring assembly goes around the
outside diameter of K3 clutch housing and
seats on B1 clutch cushion spring.

108

Technical Service Information

113

111

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09G

1004

Figure 180

111 NUMBER 2 THRUST WASHER.
113 FRONT PLANETARY ASSEMBLY.
119 NUMBER 5 THRUST BEARING.

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03C2T02168

300 035H

09G

1004

420

100

Figure 181

100 K3 CLUTCH HOUSING ASSEMBLY.
420 B1 CLUTCH APPLY RING AND RETURN SPRING ASSEMBLY.

Continued on Page 109

37. Install the completed front planetary assembly,
as shown in Figure 180, ensuring that number 5
thrust bearing and number 2 thrust washer are
still in place.
38. Front planetary assembly must be rotated back
and forth to engage K1 clutch frictions into the
planetary hub until fully seated.
39. Install K3 clutch housing assembly, as shown in
Figure 181, by rotating back and forth until it is
fully seated.
Note: K3 clutch frictions must engage on the
front planet hub, K3 clutch housing must be
engaged into B1 frictions and drive hub.

TRANSAXLE FINAL ASSEMBLY (CONT'D)

119

REAR VIEW

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03C2T02168

300 035H

09G

1004

109

Technical Service Information

Figure 182

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03C2T02168

300 035H

09G

1004

TRANSAXLE FINAL ASSEMBLY (CONT'D)

41. Measure the distance from case pump surface to
the washer surface on the K3 clutch housing, as
shown in Figure 182, using a straight edge and
ruler, or a depth micrometer.
Note: This measurement should match the
measurement taken on disassembly to ensure
that K3 clutch housing is fully seated.
42. Install "H" gage on transaxle pump surface, as
shown in Figure 183, lower the adjustment rod
to the piston surface (See Inset in Figure 183)
of the B1 apply ring/return spring assembly and
tighten the adjustment rod locking knob.
43. Now turn the "H" gage over and set it on the
completed oil pump assembly, "with" the new
design gasket, as shown in Figure 184.
44. Measure with feeler gauge between adjustment
rod and B1 clutch piston to determine the B1
clutch clearance.
45. B1 clutch clearance should be approximately
0.26 mm (.010") per friction plate installed.

Figure 183

Figure 184

Continued on Page 110

B1 Clutch Clearance Should Be

Approximately 0.26 mm (.010")

Per Friction Plate Installed

ADJUSTMENT

ROD

RETURN
SPRING

ASSEMBLY

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