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Volkswagen 01M Transmission. Manual - part 51

0240

3/16 INCH BELOW

BEARING SURFACE
NUMBERS FACE UP

NUMBER ON

BEARING

458

459

460

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.

462

458 RACE IS

INSTALLED 0N

K2 CLUTCH

HOUSING

458 RACE IS

INSTALLED 0N

K2 CLUTCH

HOUSING

462 4WD OUTPUT SHAFT AND SNAP RING.
464 OUTPUT SHAFT SEAL RINGS (2 REQUIRED).
465 NUMBER 13 THRUST BEARING.
466 NUMBER 13 THRUST BEARING RACE.

462

464

465

466

466 RACE IS

INSTALLED IN

CASE DURING

ASSEMBLY

466 RACE IS

INSTALLED IN

CASE DURING

ASSEMBLY

COMPONENT REBUILD (CONT'D)

OUTPUT SHAFT/REAR RING GEAR ASSEMBLY (CONT'D)
     4. If the caged needle bearing in output shaft needs
             replacement, try one of the local bearing supply
houses. Number DB502405W is on the bearing,
as shown in Figure 100.
     5. Install 2 new sealing rings on the output shaft, as
shown in Figure 101.
     6. Install the number 13 thrust bearing on output
             shaft, as shown in Figure 101, retain with small
amount of Trans-Jel®.
     7. Turn output shaft over and install the number 12
thrust bearing rear race and number 12 thrust
             bearing, as shown in Figure 102, retain with a
small amount of Trans-Jel®.
Note: The number 12 thrust bearing front race
             is installed on the K2 clutch housing.

Continued on Page 64

Technical Service Information

Figure 100

Figure 101

Figure 102

SNAP RING OPENING

MUST BE IN ONE OF

THE WIDE SLOTS

SNAP RING OPENING

MUST BE IN ONE OF

THE WIDE SLOTS

Technical Service Information

Figure 103

Figure 104

OUTPUT SHAFT/REAR RING GEAR ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Component Rebuild

Continued on Page 65

458 NUMBER 12 THRUST BEARING FRONT RACE.
462 COMPLETED 4WD OUTPUT SHAFT.
501 COMPLETED K2 CLUTCH HOUSING.

501

462

458

NO. 12 THRUST

BEARING AND

REAR RACE

NO. 12 THRUST

BEARING AND

REAR RACE

     8. Ensure that the number 12 thrust bearing front
             race is still stuck to the K2 clutch housing, as
shown in Figure 103.
     9. Install the completed K2 clutch housing onto the
             output shaft, as shown in Figure 103.
10. Install the rear planetary ring gear, with one of
             wide slots toward the opening in the snap ring,
             as shown in Figure 104, and onto the tabs on the
output shaft.

11. Squeeze the snap ring together using needle nose
             pliers, as shown in Figure 104, and tap ring gear
with a small hammer if necessary.
Note: Ensure that snap ring is fully seated in
             the internal groove of the rear ring gear.
12. Set completed output shaft, rear planetary ring
             gear and K2 clutch housing assembly aside for
final assembly process (See Figure 105).

Technical Service Information

REAR PLANETARY ASSEMBLY

COMPONENT REBUILD (CONT'D)

COMPLETED OUTPUT SHAFT, REAR PLANETARY

RING GEAR AND K2 CLUTCH HOUSING

COMPLETED REAR PLANETARY CARRIER

415 SPLIT "WAVE" SPRING.
416 SPRAG INNER RACE SPACER (6 TEETH ON INSIDE DIAMETER).
451 NUMBER 10 THRUST BEARING RACE.
452 NUMBER 10 THRUST BEARING.
453 REAR PL ANETARY CARRIER ASSEMBLY.

451

451 THRUST BEARING

RACE WILL BE INSTALLED

ON SMALL SUN GEAR

451 THRUST BEARING

RACE WILL BE INSTALLED

ON SMALL SUN GEAR

SPRAG RACE
SPACER AND

WAVE SPRING

SPRAG RACE
SPACER AND

WAVE SPRING

452

453

415

416

Figure 105

Figure 106

Figure 107

     1. Clean all rear planetary carrier parts thoroughly
             and dry with compressed air   (See Figure 108).
     2. Inspect all rear planetary carrier parts thoroughly
             for any wear and/or damage, and replace parts
as necessary.
3. 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.
     4. Install number 10 thrust bearing into bottom of
             planetary carrier with the needles facing up, as
shown in Figure 106.
Note: Number 10 thrust bearing race will be
installed on small sun gear.
     5. Install the sprag inner race spacer, as shown in
Figure 106.
     6. Install the split "wave" spring on top of sprag
             inner race spacer, as shown in Figure 106.
     7. Set the completed rear planetary carrier aside
for the final assembly process.

Continued on Page 66

F1 SPRAG AND RELATED PARTS, EXPLODED VIEW

408

409

410

411

410

412

411

413

414

415

416

410

408 OUTER SPRAG RACE TO CASE RETAINING SNAP RING.
(1.19 MM (.047") THICK)
409 INNER SPRAG RACE TO REAR PLANET RETAINING SNAP RING.
(1.19 MM (.047") THICK)
410 SPRAG END BEARING RETAINERS   (2 REQUIRED).
411 SPRAG END BEARINGS   ( 2 REQUIRED).
412 F1 SPRAG AND CAGE ASSEMBLY.
413 F1 SPRAG OUTER RACE.
414 F1 SPRAG INNER RACE.
415 SPLIT "WAVE" SPRING.
416 SPRAG INNER RACE SPACER   (6 TEETH ON INSIDE DIAMETER).

410 SPRAG END BEARING RETAINERS (2 REQUIRED).
413 F1 SPRAG OUTER RACE.

Technical Service Information

Figure 108

Figure 109

COMPONENT REBUILD (CONT'D)

F1 SPRAG ASSEMBLY
     1. Disassemble the complete  F1 sprag assembly
using Figure 108 as a guide.
     2. Clean all F1 sprag assembly parts thoroughly
and dry with compressed air.
     3. Inspect all F1 sprag assembly 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.
     4. Install one end bearing retainer on the back side
             of the sprag outer race, as shown in Figure 109.

Continued on Page 67

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