Volkswagen 01M Transmission. Manual — part 53
71
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AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
228
229
K1 CLUTCH HOUSING EXPLODED VIEW
230
231
232
233
234
235
236
237
238
239
240
241
400
401
236 K1 CLUTCH BALANCE PISTON.
237 K1 CLUTCH BALANCE PISTON SNAP RING.
238 K1 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
239 K1 CLUTCH FRICTION PLATES (QTY VARIES).
240 K1 CLUTCH BACKING PLATE, 4.95 MM (.195") THICK.
241 K1 CLUTCH BACKING PLATE SNAP RING, 2.5 MM (.099").
400 NUMBER 7 THRUST BEARING.
401 NUMBER 7 THRUST BEARING RACE.
228 NUMBER 6 THRUST BEARING.
229 NUMBER 6 THRUST BEARING RACE.
230 K1 CLUTCH HOUSING ASSEMBLY.
231 K1 CLUTCH HOUSING OUTER "O" RING SEAL.
232 K1 CLUTCH APPLY PISTON.
233 K1 CLUTCH APPLY PISTON INNER "O" RING SEAL.
234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
235 K1 CLUTCH BALANCE PISTON "O" RING SEAL.
K1 CLUTCH HOUSING ASSEMBLY
COMPONENT REBUILD (CONT'D)
Continued on Page 72
Figure 122
1. Disassemble the K1 clutch housing assembly
using Figure 122 as a guide.
2. Clean all K1 clutch housing parts thoroughly
and dry with compressed air.
3. Inspect all K1 clutch housing parts thoroughly
for any wear and/or damage, and replace parts
as necessary.
CAUTION: At the time of this printing, there are
not any new "hard parts" available from the
manufacturer for this unit. The only source will
be used aftermarket suppliers.
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235 K1 CLUTCH BALANCE PISTON "O" RING SEAL.
236 K1 CLUTCH BALANCE PISTON.
232 K1 CLUTCH APPLY PISTON.
233 K1 CLUTCH APPLY PISTON INNER "O" RING SEAL.
230 K1 CLUTCH HOUSING ASSEMBLY.
231 K1 CLUTCH HOUSING OUTER "O" RING SEAL.
231
232
233
230
234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
236 K1 CLUTCH BALANCE PISTON AND "O" RING SEAL.
234
236
235
236
Figure 123
Figure 124
Figure 125
Figure 126
K1 CLUTCH HOUSING ASSEMBLY (CONT'D)
COMPONENT REBUILD (CONT'D)
4. Install new inner "O" ring seal into the groove
of the K1 clutch apply piston, as shown in
Figure 123, and lube with Trans-Jel®.
5. Install new "O" ring seal into groove of the K1
clutch balance piston, as shown in Figure 124,
and lube with small amount of Trans-Jel®.
6. Turn the balance piston over and install the
return spring assembly into the holes of the
balance piston, as shown in Figure 125.
Note: Retain with a liberal amount of
Trans-Jel®.
7. Install new outer K1 clutch piston "O" ring
seal into groove of the K1 clutch housing, as
shown in Figure 126, and lube with a small
amount of Trans-Jel®.
Continued on Page 73
72
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Copyright © 2010 ATSG
Copyright © 2010 ATSG
Copyright © 2010 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
WWW.ALL-TRANS.BY
230 K1 CLUTCH HOUSING ASSEMBLY.
238 K1 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
239 K1 CLUTCH FRICTION PLATES (QTY VARIES).
240 K1 CLUTCH BACKING PLATE, 4.95 MM (.195") THICK.
241 K1 CLUTCH BACKING PLATE SNAP RING, 2.5 MM (.099").
237
236
234
232
230
230
238
239
240
241
230 K1 CLUTCH HOUSING ASSEMBLY AND "O" RING SEAL.
232 K1 CLUTCH APPLY PISTON AND "O" RING SEAL.
234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
236 K1 CLUTCH BALANCE PISTON AND "O" RING SEAL.
237 K1 CLUTCH BALANCE PISTON SNAP RING.
K1 CLUTCH HOUSING ASSEMBLY (CONT'D)
COMPONENT REBUILD (CONT'D)
8. Install the completed K1 clutch apply piston
in K1 clutch housing, as shown in Figure 127.
9. Install the completed K1 balance piston and
return spring as an assembly, as shown in
Figure 127.
10. Compress the balance piston and return spring
and install the retaining snap ring, as shown in
Figure 127.
11. Install the K1 clutch plates beginning with a
steel plate and alternating with the friction
plates, as shown in Figure 128, until you have
the proper amount installed as quantity varies.
Note: All friction plates should be soaked in
proper fluid for 30 minutes before installing.
12. Install the K1 clutch backing plate, as shown
in Figure 128, with the rounded edge facing
the friction plate (See Figure 128).
13. Install the K1 clutch backing plate snap ring,
as shown in Figure 128.
Continued on Page 74
Figure 127
Figure 128
ROUNDED EDGE
TOWARDS FRICTION
BACKING
PLATE
73
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AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
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400
401
228
229
228 INSTALLS ON
BACK SIDE OF
TURBINE SHAFT
228 INSTALLS ON
BACK SIDE OF
TURBINE SHAFT
401 THRUST BEARING
INSTALLS ON K1
CLUTCH HUB
401 THRUST BEARING
INSTALLS ON K1
CLUTCH HUB
400 NUMBER 7 THRUST BEARING.
401 NUMBER 7 THRUST BEARING RACE.
COMPLETED K1 CLUTCH HOUSING
K1 Clutch Clearance Should Be
Approximately .010" Per Friction Plate
228 NUMBER 6 THRUST BEARING.
229 NUMBER 6 THRUST BEARING RACE.
Figure 130
Figure 129
Figure 131
Figure 132
14. Measure the K1 clutch clearance with a feeler
gauge between the backing plate and snap ring,
as shown in Figure 129.
Note: There are no factory clutch clearance
specifications available, but the clearances
were the "traditional" .010" per friction plate
through-out this unit.
15. K1 clutch clearance should be approximately
.010" per friction plate installed, as shown in
Figure 129.
16. Install number 7 thrust bearing on K1 clutch
housing, as shown in Figure 130, and retain
with Trans-Jel®.
Note: Number 7 thrust bearing race installs
K1 clutch hub.
17. Turn the K1 clutch housing over and install the
number 6 thrust bearing race in the direction
shown in Figure 131 and retain with a small
amount of Trans-Jel®.
Note: Number 6 thrust bearing installs on
back side of turbine shaft.
18. Set the completed K1 clutch housing aside for
the final assembly process.
K1 CLUTCH HOUSING ASSEMBLY (CONT'D)
COMPONENT REBUILD (CONT'D)
Component Rebuild
Continued on Page 75
74
Copyright © 2010 ATSG
Copyright © 2010 ATSG
Copyright © 2010 ATSG
Copyright © 2010 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
WWW.ALL-TRANS.BY
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