Volkswagen 01M Transmission. Manual - part 49

Technical Service Information

Figure 84

Figure 85

TRANSMISSION CASE ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

13. Rotate parking pawl down into position, against
             spring tension, and install inside detent lever and
             the park rod and actuator, as shown in Figure 83.
Note: Park rod must be on the top side of the
parking pawl.
14. Lube with a small amount of Trans-Jel® and
             install the manual shaft through the case bore
             and inside detent lever, as shown in Figure 83.
15. Align and install the rolled pin through inside
             detent lever and the manual shaft, as shown in
Figure 83.
16. Install the park rod guide on top of the park rod,
             as shown in Figure 83, and torque the three bolts
to 28 N·m (20 ft.lb.).

17. After installation, the return spring must be on
             back side of the case tab and underneath the
             parking pawl, as shown in Figure 84.
18. After installation, park rod must be underneath
             the park rod guide and on top of parking pawl,
as shown in Figure 85.

Continued on Page 56

CASE TAB

RETURN SPRING MUST

BE ON BACK SIDE OF

CASE TAB AND UNDER

PARKING PAWL

RETURN SPRING MUST

BE ON BACK SIDE OF

CASE TAB AND UNDER

PARKING PAWL

PARK ROD MUST
BE UNDERNEATH

GUIDE AND ON TOP

OF PARKING PAWL

PARK ROD MUST
BE UNDERNEATH

GUIDE AND ON TOP

OF PARKING PAWL

* 20SGL

J00037

465 NUMBER 13 THRUST BEARING (INSTALLS ON OUTPUT SHAFT).
466 NUMBER 13 THRUST BEARING RACE.

465

465 IS INSTALLED

ON THE OUTPUT

SHAFT

465 IS INSTALLED

ON THE OUTPUT

SHAFT

466

31 OUTPUT SPEED SENSOR AND CONNECTOR ASSEMBLY.
32 OSS AND RETAINER BOLTS, 11.5 MM (0.452") LONG (2 REQ).
33 OUTPUT SPEED SENSOR HARNESS RETAINER.

Figure 86

Figure 87

TRANSMISSION CASE ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

19. Install the number 13 thrust bearing race into and
over case boss, as shown in Figure 86, and retain
with Trans-Jel®.
Note: The number 13 thrust bearing will be
installed on the output shaft.
20. Install output speed sensor and harness assembly
into case, as shown in Figure 87.
21. Torque both bolts to 11 N·m (97 in.lb.).
22. Set the transmission case assembly aside for the
final assembly process.

Component Rebuild

Continued on Page 57

Technical Service Information

K2 CLUTCH HOUSING EXPLODED VIEW

454

455

456

500

501

502

503

504

505

508

507

506

509

510

511

512

458

459

460

454 NUMBER 11 THRUST BEARING FRONT RACE.
455 NUMBER 11 THRUST BEARING.
456 NUMBER 11 THRUST BEARING REAR RACE.
458 NUMBER 12 THRUST BEARING FRONT RACE.
459 NUMBER 12 THRUST BEARING.
460 NUMBER 12 THRUST BEARING REAR RACE.
500 K2 CLUTCH HOUSING SEAL RING.
501 K2 CLUTCH HOUSING ASSEMBLY.
502 K2 CLUTCH HOUSING INNER "O" RING SEAL.
503 K2 CLUTCH APPLY PISTON OUTER "O" RING SEAL.

504 K2 CLUTCH APPLY PISTON.
505 K2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
506 K2 CLUTCH BALANCE PISTON "O" RING SEAL.
507 K2 CLUTCH BALANCE PISTON.
508 K2 CLUTCH BALANCE PISTON RETAINING SNAP RING.
509 K2 CLUTCH STEEL PLATES (QUANTITY VARIES).
510 K2 CLUTCH FRICTION PLATES (QUANTITY VARIES).
511 K2 CLUTCH BACKING PLATE, 4.63 MM (.182") THICK.
512 K2 CLUTCH BACKING PLATE SNAP RING, 2.46 MM (.097") THK.

Figure 88

Technical Service Information

K2 CLUTCH HOUSING

COMPONENT REBUILD (CONT'D)

     1. Disassemble the K2 clutch housing assembly
using Figure 88 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 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.

Continued on Page 58

505 K2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
507 K2 CLUTCH BALANCE PISTON AND "O" RING SEAL.

503 K2 CLUTCH APPLY PISTON OUTER "O" RING SEAL.
504 K2 CLUTCH APPLY PISTON.

507

501

502

503

504

505

501 K2 CLUTCH HOUSING ASSEMBLY.
502 K2 CLUTCH HOUSING INNER "O" RING SEAL.

Figure 90

Figure 92

Figure 91

506 K2 CLUTCH BALANCE PISTON "O" RING SEAL.
507 K2 CLUTCH BALANCE PISTON.

506

507

Figure 89

Technical Service Information

K2 CLUTCH HOUSING (CONT'D)

COMPONENT REBUILD (CONT'D)

     4. Install new "O" ring seal onto the K2 clutch
             balance piston, as shown in Figure 89.
     5. Turn the balance piston over and install the K2
             clutch piston return spring assembly, as shown
             in Figure 90, and retain with liberal amount of
Trans-Jel®.
     6. Install new outer "O" ring seal onto K2 clutch
             apply piston, as shown in Figure 91.
     7. Install new inner "O" ring seal into the lower
             groove in the K2 clutch housing, as shown in
Figure 92.

Continued on Page 59

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