Volkswagen 01M Transmission. Manual — part 54

72 NUMBER 1 THRUST WASHER (PL ASTIC).
200 K3 CLUTCH HOUSING ASSEMBLY.
201 K3 CLUTCH APPLY PISTON OUTER "O" RING SEAL.
202 K3 CLUTCH APPLY PISTON.
203 K3 CLUTCH APPLY PISTON INNER "O" RING SEAL.
204 K3 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
205 K3 CLUTCH BALANCE PISTON "O" RING SEAL.

206 K3 CLUTCH BALANCE PISTON.
207 NUMBER 2 THRUST WASHER HARDENED RACE.
208 K3 CLUTCH BALANCE PISTON SNAP RING, 1.2 MM (.047").
209 K3 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
210 K3 CLUTCH FRICTION PLATES (QTY VARIES).
211 K3 CLUTCH BACKING PLATE, 4.2 MM (.166") THICK.
212 K3 CLUTCK BACKING PLATE SNAP RING, 2.5 MM (.099").

75

Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

K3 CLUTCH HOUSING ASSEMBLY

COMPONENT REBUILD (CONT'D)

Continued on Page 76

Figure 133

4

2

K3 CLUTCH HOUSING EXPLODED VIEW

72

200

201

202

203

204

205

206

207

208

209

210

211

212

1. Disassemble the K3 clutch housing assembly
using Figure 133 as a guide.
2. Clean all K3 clutch housing parts thoroughly
and dry with compressed air.
3. Inspect all K3 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.

WWW.ALL-TRANS.BY

76

204 K3 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
206 K3 CLUTCH BALANCE PISTON, SEAL AND WASHER RACE.

204

206

Copyright © 2010 ATSG

205 K3 CLUTCH BALANCE PISTON "O" RING SEAL.
206 K3 CLUTCH BALANCE PISTON.
207 NUMBER 2 THRUST WASHER HARDENED RACE.

205

206

207

Copyright © 2010 ATSG

201

202

203

201 K3 CLUTCH APPLY PISTON OUTER "O" RING SEAL.
202 K3 CLUTCH APPLY PISTON.
203 K3 CLUTCH APPLY PISTON INNER "O" RING SEAL.

Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

200 K3 CLUTCH HOUSING ASSEMBLY.
202 COMPLETED K3 CLUTCH APPLY PISTON.

200

202

Copyright © 2010 ATSG

Figure 134

Figure 135

Figure 137

Figure 136

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)
4. Install new inner and outer "O" ring seals onto
K3 clutch apply piston and lube with a small
amount of Trans-Jel® (See Figure 134).
5. Install new "O" ring seal on K3 clutch balance
piston, as shown in Figure 135, and lube with
a small amount of Trans-Jel®.
6. Install the number 2 thrust washer race onto
balance piston, as shown in Figure 135, and
retain with Trans-Jel®.

7. Install the apply piston return spring assembly
to the bottom of balance piston, as shown in
Figure 136, and retain with Trans-Jel®.
8. Lube the seal surfaces of K3 clutch housing
and install completed K3 clutch apply piston,
as shown in Figure 137.

Continued on Page 77

WWW.ALL-TRANS.BY

200 K3 CLUTCH HOUSING ASSEMBLY.
206 COMPLETED K3 CLUTCH BALANCE PISTON ASSEMBLY.
208 k3 CLUTCH BALANCE PISTON SNAP RING, 1.2 MM (.047").

77

200 K3 CLUTCH HOUSING ASSEMBLY.
209 K3 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
210 K3 CLUTCH FRICTION PLATES (QTY VARIES).
211 K3 CLUTCH BACKING PLATE, 4.2 MM (.166") THICK.
212 K3 CLUTCK BACKING PLATE SNAP RING, 2.5 MM (.099").

200

42

210

209

211

212

Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

200

206

208

Copyright © 2010 ATSG

ROUNDED EDGE

TOWARDS FRICTION

BACKING

PLATE

Figure 138

Figure 139

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)

Continued on Page 78

9. Install the completed K3 balance piston and
return spring as an assembly, as shown in
Figure 138.
10. Compress the balance piston and return spring
and install the retaining snap ring, as shown in
Figure 138.
11. Install the K3 clutch plates beginning with a
steel plate and alternating with the friction
plates, as shown in Figure 139, 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 K3 clutch backing plate, as shown
in Figure 139, with the rounded edge facing
the friction plate.
13. Install the K3 clutch backing plate snap ring,
as shown in Figure 139.

WWW.ALL-TRANS.BY

42

COMPLETED K3 CLUTCH HOUSING

42

K3 Clutch Clearance Should Be

Approximately .010" Per Friction Plate

72 NUMBER 1 THRUST WASHER (PL ASTIC).
200 K3 CLUTCH HOUSING ASSEMBLY.

42

200

72

FITS

EITHER

WAY

FITS

EITHER

WAY

78

Copyright © 2010 ATSG

Copyright © 2010 ATSG

Copyright © 2010 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 140

Figure 141

Figure 142

14. Measure the K3 clutch clearance with a feeler
gauge between the backing plate and snap ring,
as shown in Figure 140.
Note: There are no factory clutch clearance
specifications available, but the clearances
were the "traditional" .010" per friction plate
through-out this unit.

15. K3 clutch clearance should be approximately
.010" per friction plate installed, as shown in
Figure 140.
16. Turn the K3 clutch housing over and install the
number 1 thrust washer, engaging the tabs of
the washer in housing, as shown in Figure 141.
17. Set the completed K3 clutch housing aside for
the final assembly process (See Figure 142).

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)

The next 2 components in "Component Rebuild"
section have changes in the components, that are not
interchangeable, and related to whether you have a
"2-Port" or a "3-Port" torque converter. This
requires an understanding of how each of these
converters operate hydraulically and the description
begins on Page 79, along with the dimensional
differences in the affected parts.

Component Rebuild Section

Continues on Page 82

CAUTION!

WWW.ALL-TRANS.BY