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Volkswagen 01M Transmission. Manual - part 53

Technical Service Information

228

229

K1 CLUTCH HOUSING EXPLODED VIEW

230

231

232

233

234

235

236

237

238

239

240

241

400

401

236 K1 CLUTCH BALANCE PISTON.
237 K1 CLUTCH BALANCE PISTON SNAP RING.
238 K1 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
239 K1 CLUTCH FRICTION PLATES (QTY VARIES).
240 K1 CLUTCH BACKING PLATE, 4.95 MM (.195") THICK.
241 K1 CLUTCH BACKING PLATE SNAP RING, 2.5 MM (.099").
400 NUMBER 7 THRUST BEARING.
401 NUMBER 7 THRUST BEARING RACE.

228 NUMBER 6 THRUST BEARING.
229 NUMBER 6 THRUST BEARING RACE.
230 K1 CLUTCH HOUSING ASSEMBLY.
231 K1 CLUTCH HOUSING OUTER "O" RING SEAL.
232 K1 CLUTCH APPLY PISTON.
233 K1 CLUTCH APPLY PISTON INNER "O" RING SEAL.
234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
235 K1 CLUTCH BALANCE PISTON "O" RING SEAL.

K1 CLUTCH HOUSING ASSEMBLY

COMPONENT REBUILD (CONT'D)

Continued on Page 72

Figure 122

     1. Disassemble the K1 clutch housing assembly
using Figure 122 as a guide.
     2. Clean all K1 clutch housing parts thoroughly
and dry with compressed air.
     3. Inspect all K1 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.

235 K1 CLUTCH BALANCE PISTON "O" RING SEAL.
236 K1 CLUTCH BALANCE PISTON.

232 K1 CLUTCH APPLY PISTON.
233 K1 CLUTCH APPLY PISTON INNER "O" RING SEAL.

230 K1 CLUTCH HOUSING ASSEMBLY.
231 K1 CLUTCH HOUSING OUTER "O" RING SEAL.

231

232

233

230

234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
236 K1 CLUTCH BALANCE PISTON AND "O" RING SEAL.

234

236

235

236

Figure 123

Figure 124

Figure 125

Figure 126

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

     4. Install new inner "O" ring seal into the groove
             of the K1 clutch apply piston, as shown in
Figure 123, and lube with Trans-Jel®.
     5. Install new "O" ring seal into groove of the K1
             clutch balance piston, as shown in Figure 124,
and lube with small amount of Trans-Jel®.
     6. Turn the balance piston over and install the
             return spring assembly into the holes of the
             balance piston, as shown in Figure 125.
Note:   Retain with a liberal amount of
Trans-Jel®.
     7. Install new outer K1 clutch piston "O" ring
             seal into groove of the K1 clutch housing, as
             shown in Figure 126, and lube with a small
amount of Trans-Jel®.

Continued on Page 73

Technical Service Information

230 K1 CLUTCH HOUSING ASSEMBLY.
238 K1 CLUTCH STEEL PLATES, 2.0 MM (.079") THK (QTY VARIES).
239 K1 CLUTCH FRICTION PLATES (QTY VARIES).
240 K1 CLUTCH BACKING PLATE, 4.95 MM (.195") THICK.
241 K1 CLUTCH BACKING PLATE SNAP RING, 2.5 MM (.099").

237

236

234

232

230

238

239

240

241

230 K1 CLUTCH HOUSING ASSEMBLY AND "O" RING SEAL.
232 K1 CLUTCH APPLY PISTON AND "O" RING SEAL.
234 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
236 K1 CLUTCH BALANCE PISTON AND "O" RING SEAL.
237 K1 CLUTCH BALANCE PISTON SNAP RING.

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

     8. Install the completed K1 clutch apply piston
             in K1 clutch housing, as shown in Figure 127.
     9. Install the completed K1 balance piston and
             return spring as an assembly, as shown in
Figure 127.
10. Compress the balance piston and return spring
             and install the retaining snap ring, as shown in
Figure 127.
11. Install the K1 clutch plates beginning with a
             steel plate and alternating with the friction
             plates, as shown in Figure 128, 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 K1 clutch backing plate, as shown
             in Figure 128, with the rounded edge facing
the friction plate (See Figure 128).
13. Install the K1 clutch backing plate snap ring,
as shown in Figure 128.

Continued on Page 74

Figure 127

Figure 128

ROUNDED EDGE

TOWARDS FRICTION

BACKING

PLATE

Technical Service Information

400

401

228

229

228 INSTALLS ON

BACK SIDE OF

TURBINE SHAFT

228 INSTALLS ON

BACK SIDE OF

TURBINE SHAFT

401 THRUST BEARING

INSTALLS ON K1

CLUTCH HUB

401 THRUST BEARING

INSTALLS ON K1

CLUTCH HUB

400 NUMBER 7 THRUST BEARING.
401 NUMBER 7 THRUST BEARING RACE.

COMPLETED K1 CLUTCH HOUSING

K1 Clutch Clearance Should Be

Approximately .010" Per Friction Plate

228 NUMBER 6 THRUST BEARING.
229 NUMBER 6 THRUST BEARING RACE.

Figure 130

Figure 129

Figure 131

Figure 132

14. Measure the K1 clutch clearance with a feeler
gauge between the backing plate and snap ring,
as shown in Figure 129.
Note: There are no factory clutch clearance
specifications available, but the clearances
were the "traditional" .010" per friction plate
through-out this unit.

15. K1 clutch clearance should be approximately
             .010" per friction plate installed, as shown in
Figure 129.
16. Install number 7 thrust bearing on K1 clutch
             housing, as shown in Figure 130, and retain
with Trans-Jel®.
Note: Number 7 thrust bearing race installs
K1 clutch hub.
17. Turn the K1 clutch housing over and install the
             number 6 thrust bearing race in the direction
             shown in Figure 131 and retain with a small
amount of Trans-Jel®.
Note: Number 6 thrust bearing installs on
back side of turbine shaft.
18. Set the completed K1 clutch housing aside for
the final assembly process.

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Component Rebuild

Continued on Page 75

Technical Service Information

Content .. 51 52 53 54 ..