Volkswagen 01M Transmission. Manual — part 111

123 K1 CLUTCH FRICTION PLATES (QUANTITY MAY VARY).
124 K1 CLUTCH STEEL PLATES (QUANTITY MAY VARY).
131 K1 CLUTCH HOUSING ASSEMBLY.

123

131

124

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AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

13. Install K1 clutch pack beginning with a steel
plate and alternating with frictions, as shown in
Figure 116, 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.

131

128

127

126

125

125 K1 CLUTCH BALANCE PISTON SNAP RING.
126 K1 CLUTCH BALANCE PISTON.
127 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
128 K1 CLUTCH APPLY PISTON.
131 K1 CLUTCH HOUSING ASSEMBLY.

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

9. Lubricate the seal surfaces of K1 clutch apply
piston and install the piston into K1 clutch
housing, as shown in Figure 115
10. Install the K1 clutch apply piston return spring,
as shown in Figure 115, and ensure springs are
engaged in apply piston spring pockets.
11. Lube the balance piston seal and install piston,
as shown in Figure 115.
12. Compress the balance piston and install the
snap ring, as shown in Figure 115.

Figure 115

Figure 116

COMPONENT REBUILD (CONT'D)

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AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

8

Factory K1 Clutch Clearance

Was 1.42 MM (.056")

With 5 Frictions

8

131

134

8

120 NUMBER 5 THRUST BEARING RACE.
121 K1 CLUTCH BACKING PLATE SNAP RING, 1.62MM (.064") THICK.
122 K1 CLUTCH BACKING PLATE.

120 NUMBER 5 THRUST BEARING RACE.
131 COMPLETED K1 CLUTCH HOUSING.
134 COMPLETED K3 CLUTCH HOUSING DRIVE HUB.

122

121

ID STAMP

Figure 117

Figure 119

Figure 118

14. Install the K1 clutch backing plate on top of
the last friction, as shown in Figure 117, with
step side facing up.
Note: Notice the number stamped on top side
of backing plate, which is an indicator that it
is selective, but as yet, no selectives available.
15. Install the K1 clutch backing plate snap ring,
as shown in Figure 117.
Note: This snap ring is .064" thick.
16. Measure the K1 clutch clearance with a feeler
gauge between the backing plate and friction
plate, as shown in Figure 118.
Note: There are no factory clutch clearance
specifications available, but the clearances
were the "traditional" .010" per friction plate
through-out this unit. Refer to Figure 118
for K1 clutch clearance with 5 frictions.
17. Install number 5 thrust bearing race on the hub
of K1 clutch housing, as shown in Figure 117,
and retain with Trans-Jel®.

18. Install completed K1 clutch housing into the
completed K3 clutch housing drive hub, as
shown in Figure 119 and set aside for the final
assembly process.

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Component Rebuild

Continued on Page 76

120

120

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471

472 473

500

501

504

505

506

507

508

509

510

511

512

513

502

503

471 NUMBER 9 "FRONT" THRUST BEARING RACE.
472 NUMBER 9 THRUST BEARING.
473 NUMBER 9 "REAR" THRUST BEARING RACE.
500 K2 CLUTCH BACKING PLATE SNAP RING (.065" THICKNESS).
501 K2 CLUTCH BACKING PLATE, .114".
502 K2 CLUTCH FRICTION PLATES (QUANTITY MAY VARY).
503 K2 CLUTCH STEEL PLATES , .071" (QUANTITY MAY VARY).
504 K2 CLUTCH BALANCE PISTON SNAP RING.
505 K2 CLUTCH "MOULDED" BALANCE PISTON.

506 K2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
507 K2 CLUTCH APPLY PISTON RETURN SPRING SEAT.
508 K2 CLUTCH "MOULDED" APPLY PISTON.
509 K2 CLUTCH BALANCE PISTON INNER "O" RING SEAL (THIN).
510 K2 CLUTCH APPLIY PISTON INNER "O" RING SEAL (THICK).
511 K2 CLUTCH HOUSING ASSEMBLY.
512 NUMBER 11 THRUST BEARING.
513 NUMBER 11 THRUST BEARING RACE.

K2 CLUTCH AND ASSOCIATED PARTS, EXPLODED VIEW

COMPONENT REBUILD (CONT'D)

K2 CLUTCH HOUSING ASSEMBLY

1. Disassemble the K2 clutch housing assembly
using Figure 120 as a guide.
2. Clean all K2 clutch housing parts thoroughly
and dry with compressed air.
3. Inspect all K2 clutch housing parts thoroughly
for wear and/or damage, replace as necessary.

WARNING: At 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.

Continued on Page 77

Figure 120

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Technical Service Information

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K2 CLUTCH HOUSING ASSEMBLY (CONT'D)

4. Install the K2 apply piston inner "O" ring seal
in the bottom groove of housing, as shown in
Figure 121.
Note: Body of this "O" ring measures .105".
5. Install the K2 balance piston inner "O" ring
seal in the center groove of housing, as shown
in Figure 121.
Note: Body of this "O" ring measures .055".
6. Install the K2 return spring assembly to the
spring seat, as shown in Figure 122, and retain
with Trans-Jel®.

COMPONENT REBUILD (CONT'D)

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AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

504 K2 CLUTCH BALANCE PISTON SNAP RING.
505 K2 CLUTCH "MOULDED" BALANCE PISTON.
506 K2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
507 K2 CLUTCH APPLY PISTON RETURN SPRING SEAT.
508 K2 CLUTCH "MOULDED" APPLY PISTON.
511 K2 CLUTCH HOUSING ASSEMBLY.

506 K2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
507 K2 CLUTCH APPLY PISTON RETURN SPRING SEAT.

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509 K2 CLUTCH BALANCE PISTON INNER "O" RING SEAL (THIN).
510 K2 CLUTCH APPLIY PISTON INNER "O" RING SEAL (THICK).
511 K2 CLUTCH HOUSING ASSEMBLY.

511

511

506

506

505

504

507

508

507

510

509

7. Lubricate the seal surfaces of K2 clutch apply
piston and install the piston into K2 clutch
housing, as shown in Figure 123
8. Install K2 clutch piston return spring assembly,
as shown in Figure 123.
9. Lube the balance piston seal and install piston,
as shown in Figure 123.
10. Compress the balance piston and install the
snap ring, as shown in Figure 123.

Figure 121

Figure 122

Figure 123

Continued on Page 78

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