Volkswagen 01M Transmission. Manual - part 52

COMPLETED F1 SPRAG ASSEMBLY

67

Technical Service Information

Figure 110

Figure 112

Figure 111

413

413

414

"SQUARE CUT"

POCKET

"SQUARE CUT"

POCKET

"CHAMFERED"

POCKET

"CHAMFERED"

POCKET

411

408

409

411

410

412

INSTALLED

END BEARING

RETAINER

INSTALLED

END BEARING

RETAINER

 410  SPRAG END BEARING RETAINERS   (2 REQUIRED).
 411  SPRAG END BEARINGS   ( 2 REQUIRED).
 412  F1 SPRAG AND CAGE ASSEMBLY.
 413  F1 SPRAG OUTER RACE.

 413  F1 SPRAG OUTER RACE.
 414  F1 SPRAG INNER RACE.

 408  OUTER RACE TO CASE SNAP RING   (1.19 MM (.047") THICK).
 409  INNER RACE TO PLANE T SNAP RING  (1.2 MM (.047") THICK).

COMPONENT REBUILD (CONT'D)

F1 SPRAG ASSEMBLY (CONT'D)
     5. Turn the outer race and retainer over, as shown
             in Figure 110, and install sprag end bearing with
       groove facing up.
     6. Install the F1 sprag assembly with lip facing 
             down and "windows" to the right, as shown in
       Figure 110.
     7. Install the second end bearing with the groove
             facing down, as shown in Figure 110.
     8. Install the second end bearing retainer, as shown
             in Figure 110, by snapping into place and ensure
       that it is fully seated.
     9. Turn F1 sprag assembly over again and install 
             the F1 sprag inner race with the "square cut"
             pocket facing up, as shown in Figure 111.
       Note: With the F1 sprag sprag assembly in this
             position, sprag inner race will freewheel in a
       counter-clockwise direction.

 10. Turn the F1 sprag assembly over once again, as 
             shown in Figure 112, which is the direction it is
       installed into transmission.
       Note: In this position sprag inner race should 
       freewheel clockwise and "chamfered" pocket
       shoud be facing up.
 11. Set the completed F1 sprag assembly aside for
       the final assembly process.

Component Rebuild

Continued on Page 68

REAR GEAR TRAIN AND ASSOCIATED PARTS, EXPLODED VIEW

401

402

403

404

405

406

407

400

450

450

451

451

452

453

415

416

 400  NUMBER 7 THRUST BEARING.
 401  NUMBER 7 THRUST BEARING RACE.
 402  K1 CLUTCH HUB.
 403  NUMBER 8 THRUST BEARING RACE.
 404  NUMBER 8 THRUST BEARING.
 405  L ARGE REAR SUN GEAR AND SHELL ASSEMBLY.
 406  NUMBER 9 THRUST BEARING.

 407  NUMBER 9 THRUST BEARING RACE.
 415  SPLIT "WAVE" SPRING.
 416  SPRAG INNER RACE SPACER   (6 TEETH ON INSIDE DIAMETER).
 450  SMALL REAR SUN GEAR AND SHAFT ASSEMBLY.
 451  NUMBER 10 THRUST BEARING RACE.
 452  NUMBER 10 THRUST BEARING.
 453  REAR PL ANETARY CARRIER ASSEMBLY.

 450  SMALL REAR SUN GEAR AND SHAFT ASSEMBLY.
 451  NUMBER 10 THRUST BEARING RACE.

SUN GEARS AND THRUST BEARINGS

COMPONENT REBUILD (CONT'D)

Continued on Page 69

Figure 113

Figure 114

68

Technical Service Information

     1. Exploded view of sun gears and associated parts
       is shown in Figure 113.
     2. Clean all sun gear parts thoroughly and dry with
       compressed air.
     3. Inspect all sun gear parts thoroughly for any
       wear and/or damage, replace as necessary.
     4. Install the number 10 thrust bearing race onto 
             the small sun gear, as shown in Figure 114, and
       retain with small amount of Trans-Jel®.
     5. Set the small sun gear assembly aside for the
       final assembly process  (See Figure 115).

403

404

405

403 THRUST BEARING

RACE INSTALLS ON

K1 CLUTCH HUB

403 THRUST BEARING

RACE INSTALLS ON

K1 CLUTCH HUB

 403  NUMBER 8 THRUST BEARING RACE.
 404  NUMBER 8 THRUST BEARING.
 405  L ARGE REAR SUN GEAR AND SHELL ASSEMBLY.

69

Technical Service Information

406

405

407

407 THRUST BEARING

RACE INSTALLS ON

REAR PLANETARY

DURING ASSEMBLY

407 THRUST BEARING

RACE INSTALLS ON

REAR PLANETARY

DURING ASSEMBLY

 405  L ARGE REAR SUN GEAR AND SHELL ASSEMBLY.
 406  NUMBER 9 THRUST BEARING.
 407  NUMBER 9 THRUST BEARING RACE.

Figure 115

Figure 116

Figure 118

Figure 117

   8. Set the completed large sun gear and shell aside
           for the final assembly process (See Figure 118).

     6. Install number 9 thrust bearing on sun gear shell,
             with needles facing up, as shown in Figure 116,
       retain with Trans-Jel®.
       Note: Number 9 thrust bearing race installs on
       rear carrier during final assembly process.
     7. Turn sun gear shell over and install number 8 
             thrust bearing into sun gear shell with needles
             facing up, as shown in Figure 117, retain with
       Trans-Jel®.
       Note: Number 8 thrust bearing race installs on
       K1 clutch hub  (See Figure 119).

COMPLETED LARGE SUN GEAR AND SHELL

SUN GEARS AND THRUST BEARINGS (CONT'D)

COMPONENT REBUILD (CONT'D)

COMPLETED SMALL SUN GEAR

Continued on Page 70

 400  NUMBER 7 THRUST BEARING.
 401  NUMBER 7 THRUST BEARING RACE.
 402  K1 CLUTCH HUB.

401

402

400 THRUST BEARING

INSTALLED ON K1

CLUTCH HOUSING

400 THRUST BEARING

INSTALLED ON K1

CLUTCH HOUSING

400

Figure 119

Figure 120

Figure 121

COMPLETED K1 CLUTCH HUB

     9. Install number 8 thrust bearing race on the back
             side of K1 clutch hub, as shown in Figure 119,
       and retain with Trans-Jel®.
 10. Turn K1 clutch hub over and install number 7 
             thrust bearing race, as shown in Figure 120, and
       retain with Trans-Jel®.
       Note: Number 7 thrust bearing is installed on
       back side of K1 clutch housing.
 11. Set the K1 clutch hub assembly aside for the
       final assembly process  (See Figure 121).

SUN GEARS AND THRUST BEARINNGS (CONT'D)

COMPONENT REBUILD (CONT'D)

402

403

 402  K1 CLUTCH HUB.
 403  NUMBER 8 THRUST BEARING RACE.

Component Rebuild

Continued on Page 71

70

Technical Service Information