Volkswagen 01M Transmission. Manual - part 47

47

Technical Service Information

   The output shaft, the rear planetary ring gear and the 
K2 clutch housing are removed as an assembly and 
installed as an assembly.  The K2 clutch housing 
cannot be removed with out seperating the rear 
planetary ring gear from the output shaft.  They are 
connected with an internal snap ring in the output 
shaft that locks into an internal groove in the rear 
planetary ring gear.

 458  NUMBER 12 THRUST BEARING FRONT RACE.
 459  NUMBER 12 THRUST BEARING.
 460  NUMBER 12 THRUST BEARING REAR RACE.
 462  4WD OUTPUT SHAFT AND SNAP RING ASSEMBLY.
 501  K2 CLUTCH HOUSING COMPLETE.

501

460

459

458

462

TRANSMISSION DISASSEMBLY (CONT'D)

Figure 69

Figure 70

 63. Squeeze the internal snap ring together using a
             pair of needle nose pliers, as shown in Figure 69,
             to release the rear planetary ring gear.
       Note: An assistant may have to tap on the ring
             gear to move it off the snap ring.

 64. Seperate the output shaft, rear planetary ring gear
             and K2 clutch housing, as shown in Figure 70,
             and set aside for the component rebuild process.
       Note: The number 12 thrust bearing front race
             may be stuck to the back of K2 clutch housing.

Continued on Page 48

48

Technical Service Information

* 20SGL

 J00037

465

466

 465  NUMBER 13 THRUST BEARING.
 466  NUMBER 13 THRUST BEARING RACE.

 422  B2 CLUTCH APPLY PISTON RETURN SPRING SNAP RING.
 423  B2 CLUTCH APPLY PISTON.

AD

APT

-A

-CASE

"THE DRUM BUDDY" BY ADAPT-A-CASE

* 

20SGL

 J00037

SNAP RING

0.80 MM (0.031")

THICKNESS

SNAP RING

0.80 MM (0.031")

THICKNESS

422

423

Figure 73

Figure 72

Figure 71

TRANSMISSION DISASSEMBLY (CONT'D)

Continued on Page 50

 65. Remove the number 13 thrust bearing and thrust
             bearing race, as shown in Figure 71.
       Note: Number 13 thrust bearing may be stuck
             to back side of the output shaft.
 66. Compress the B2 clutch piston return spring 
       assembly and remove the snap ring.
       Note: This is a deep case and the compressor
       from "Adapt-A-Case", shown in Figure 72,
             gave great access to the snap ring and worked 
       very well.
 67. Remove snap ring and return spring assembly
             from the case, as shown in Figure 73.

CAUTION: The parking pawl and all linkage 
"must" be removed from the case "before" the 
B2 clutch piston can be removed, as the parking 
pawl passes through the piston.

49

Technical Service Information

TRANSMISSION CASE EXPLODED VIEW

100

101

101

102

103

104

105

106

107

108

109

110

111

112

113

116

117

114

115

 106  OUTSIDE MANUAL LEVER.
 107  LOCKING WASHER.
 108  RETAINING NUT.
 109  DETENT SPRING RETAINING BOLT 15.45 MM (0.608") LONG.
 110  INSIDE DETENT SPRING.
 111  INSIDE DETENT SPRING SPACER.
 112  ACTUATOR GUIDE RETAINING BOLT, 18.45 MM (0.726") (3 REQ).
 113  PARKING ROD ACTUATOR GUIDE.
 114  PARKING PAWL RETURN SPRING.
 115  PARKING PAWL PIVOT PIN.
 116  PARKING PAWL PIVOT PIN "E" CLIP.
 117  PARKING PAWL.

 100  TRANSMISSION CASE ASSEMBLY.
 101  MANUAL SHAFT SEALS   (2 REQUIRED).
 102  PARKING ROD AND ACTUATOR ASSEMBLY.
 103  ROLLED PIN.
 104  INSIDE DETENT LEVER.
 105  MANUAL SHAFT.

Figure 74

50

Technical Service Information

* 20SGL

 J00037

424

 472  B2 CLUTCH APPLY PISTON.

MADE I

N U.S.A

MADE I

N U.S.A

MADE

 IN

 U.

S.A

MADE

 IN

 U.

S.A

TRANSMISSION DISASSEMBLY (CONT'D)

Continued on Page 51

 68. Remove the "rolled" pin from the inside detent
             lever using a 3/16" punch and hammer.
       Note: There is a safety band around the inside
             detent lever that must be removed first.   Only
             way to get it off is to break it and discard it.
             The safety band will not be reused.
 69. Remove the manual shaft from the right hand
             side of case, as shown in Figure 74, by sliding it
             out through the inside detent lever and case bore.
 70. Remove the inside detent lever and park rod, as
       shown in Figure 74.
       Note: It is not necessary to remove the inside 
       detent spring unless damaged. 
 71. Remove the 3 bolts from park rod guide and
             remove park rod guide, as shown in Figure 74.

 72. Rotate park pawl to straight up position which
       will relieve the return spring tension.
 73. Remove the park pawl return spring, park pawl
             pivot pin and park pawl, as shown in Figure 74.
 74. Now, you can remove the B2 clutch apply piston,
       as shown in Figure 75.
       Note: There are two passages to the B2 clutch
             piston that can be charged with air to loosen
             the piston, as shown in Figure 76.
 75. Remove and discard the manual shaft seals and 
             notice that there is one on each side of the case.

Figure 76

Figure 75

B2 CLUTCH PASSAGE IDENTIFICATION