Volkswagen 01M Transmission. Manual — part 112

11. Install the K2 clutch pack beginning with a steel
plate and alternating with frictions, as shown in
Figure 124, 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.

K2 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

78

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503

502

511

500

500 K2 CLUTCH BACKING PLATE SNAP RING (.065" THICKNESS).
501 K2 CLUTCH BACKING PLATE.
502 K2 CLUTCH FRICTION PLATES (QUANTITY MAY VARY).
503 K2 CLUTCH STEEL PLATES (QUANTITY MAY VARY).
511 K2 CLUTCH HOUSING ASSEMBLY.

Factory K2 Clutch Clearance

Was 0.74 MM (.029")

With 3 Frictions

Figure 124

Figure 125

12. Install the K2 clutch backing plate on top of
the last friction, as shown in Figure 124, with
step side facing up.
13. Install the K2 clutch backing plate snap ring,
as shown in Figure 124.
Note: This snap ring is .065" thick.
14. Measure the K2 clutch clearance with a feeler
gauge between the backing plate and friction
plate, as shown in Figure 125.
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 125
for K2 clutch clearance with 3 frictions.

Continued on Page 79

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471

DO NOT

INSTALL

472

473

15. Turn the K2 clutch housing assembly over and
install the number 11 thrust bearing, as shown
in Figure 126, with the needles facing up.
16. Retain the number 11 thrust bearing with liberal
amount of Trans-Jel®.
17. Turn the K2 clutch housing assembly over again
and install the number 9 "rear" thrust bearing
race, as shown in Figure 127, and retain with a
small amount of Trans-Jel®.
18. Install the K2 clutch housing number 9 thrust
bearing, as shown in Figure 127, and retain with
Trans-Jel®.
Note: "Do Not" install the number 9 "front"
thrust bearing race (471) illustrated in
Figure 127. This will be installed on the rear
sun gear of the rear planetary.
19. Set the completed K2 clutch housing aside for
the final assembly process.

K2 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Component Rebuild

Continued on Page 80

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473

511

511 K2 CLUTCH HOUSING ASSEMBLY.
512 NUMBER 11 THRUST BEARING.

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COMPLETED K2 CLUTCH HOUSING

Figure 126

Figure 128

Figure 127

471 NUMBER 9 "FRONT" THRUST BEARING RACE.
472 NUMBER 9 THRUST BEARING.
473 NUMBER 9 "REAR" THRUST BEARING RACE.
511 K2 CLUTCH HOUSING ASSEMBLY.

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462

463

464

465

FRONT SUN

GEAR CANNOT

BE REMOVED

466

467

468

469

470

471

472 473

462 F1 ROLLER CLUTCH SNAP RING (.048" THICKNESS).
463 F1 ROLLER CLUTCH ASSEMBLY.
464 NUMBER 7 THRUST WASHER (BRONZE).
465 REAR PLANETARY "RAVIGNEAUX" GEAR SET.
466 NUMBER 10 THRUST WASHER (PLASTIC).
467 NUMBER 8 "FRONT" THRUST BEARING RACE.

468 NUMBER 8 THRUST BEARING.
469 NUMBER 8 "REAR" THRUST BEARING RACE.
470 REAR SUN GEAR.
471 NUMBER 9 "FRONT" THRUST BEARING RACE.
472 NUMBER 9 THRUST BEARING.
473 NUMBER 9 "REAR" THRUST BEARING RACE.

REAR PLANETARY GEAR SET AND ASSOCIATED PARTS, EXPLODED VIEW

REAR PLANETARY ASSEMBLY

COMPONENT REBUILD (CONT'D)

Figure 129

1. Disassemble the rear planetary assembly using
Figure 129 as a guide.
Note: Front sun gear is captured and cannot
be removed from rear planetary carrier.
3. Clean all rear planetary parts thoroughly and
dry with compressed air.
3. Inspect all rear planetary parts thoroughly for
any 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.

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REAR PLANETARY ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Sun Gear

Shafts

Number 8

Thrust Bearing

Blocks

4. Place the rear planetary carrier on a flat work
surface, as shown in Figure 130.
5. Install the number 7 thrust washer, as shown in
Figure 130, and retain with Trans-Jel®.
Note: This is the only "bronze" washer.
6. Install the F1 roller clutch onto the planetary
carrier, as shown in Figure 130, by rotating
carefully in a counter-clockwise direction until
fully seated.

7. Turn the rear carrier assembly over and place
on a set of appropriate blocks with front side
facing down, as shown in Figure 131.
Note: The rear carrier must be placed on the
blocks as shown, to allow the front sun gear
and shaft to seat on the inside of the carrier.
If sun gear is not down, the number 8 thrust
bearing and front race will not seat properly,
and it must seat into a pocket cut in the front
sun gear.
Refer to the cut-away in Figure 132.

Figure 132

Figure 130

Blocks

Figure 131

463

464

465

463 F1 ROLLER CLUTCH ASSEMBLY.
464 NUMBER 7 THRUST WASHER (BRONZE).
465 REAR PLANETARY "RAVIGNEAUX" GEAR SET.

Continued on Page 82

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