Volkswagen 01M Transmission. Manual - part 54

    72  NUMBER 1 THRUST WASHER (PL ASTIC).
 200  K3 CLUTCH HOUSING ASSEMBLY.
 201  K3 CLUTCH APPLY PISTON OUTER "O" RING SEAL.
 202  K3 CLUTCH APPLY PISTON.
 203  K3 CLUTCH APPLY PISTON INNER "O" RING SEAL.
 204  K3 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
 205  K3 CLUTCH BALANCE PISTON "O" RING SEAL.

 206  K3 CLUTCH BALANCE PISTON.
 207  NUMBER 2 THRUST WASHER HARDENED RACE.
 208  K3 CLUTCH BALANCE PISTON SNAP RING, 1.2 MM (.047").
 209  K3 CLUTCH STEEL PLATES, 2.0 MM (.079") THK   (QTY VARIES).
 210  K3 CLUTCH FRICTION PLATES   (QTY VARIES).
 211  K3 CLUTCH BACKING PLATE, 4.2 MM (.166") THICK.
 212  K3 CLUTCK BACKING PLATE SNAP RING, 2.5 MM (.099").

75

Technical Service Information

K3 CLUTCH HOUSING ASSEMBLY

COMPONENT REBUILD (CONT'D)

Continued on Page 76

Figure 133

4

2

K3 CLUTCH HOUSING EXPLODED VIEW

72

200

201

202

203

204

205

206

207

208

209

210

211

212

     1. Disassemble the K3 clutch housing assembly 
       using Figure 133 as a guide.
     2. Clean all K3 clutch housing parts thoroughly 
       and dry with compressed air.
     3. Inspect all K3 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.

76

 204  K3 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
 206  K3 CLUTCH BALANCE PISTON, SEAL AND WASHER RACE.

204

206

 205  K3 CLUTCH BALANCE PISTON "O" RING SEAL.
 206  K3 CLUTCH BALANCE PISTON.
 207  NUMBER 2 THRUST WASHER HARDENED RACE.

205

206

207

201

202

203

 201  K3 CLUTCH APPLY PISTON OUTER "O" RING SEAL.
 202  K3 CLUTCH APPLY PISTON.
 203  K3 CLUTCH APPLY PISTON INNER "O" RING SEAL.

Technical Service Information

 200  K3 CLUTCH HOUSING ASSEMBLY.
 202  COMPLETED K3 CLUTCH APPLY PISTON.

200

202

Figure 134

Figure 135

Figure 137

Figure 136

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)
     4. Install new inner and outer "O" ring seals onto 
             K3 clutch apply piston and lube with a small 
       amount of Trans-Jel®  (See Figure 134).
     5. Install new "O" ring seal on K3 clutch balance
             piston, as shown in Figure 135, and lube with
       a small amount of Trans-Jel®.
     6. Install the number 2 thrust washer race onto 
             balance piston, as shown in Figure 135, and
       retain with Trans-Jel®.

     7. Install the apply piston return spring assembly
             to the bottom of balance piston, as shown in
       Figure 136, and retain with Trans-Jel®.
     8. Lube the seal surfaces of K3 clutch housing 
             and install completed K3 clutch apply piston,
       as shown in Figure 137.

Continued on Page 77

 200  K3 CLUTCH HOUSING ASSEMBLY.
 206  COMPLETED K3 CLUTCH BALANCE PISTON ASSEMBLY.
 208  k3 CLUTCH BALANCE PISTON SNAP RING, 1.2 MM (.047").

77

 200  K3 CLUTCH HOUSING ASSEMBLY.
 209  K3 CLUTCH STEEL PLATES, 2.0 MM (.079") THK   (QTY VARIES).
 210  K3 CLUTCH FRICTION PLATES   (QTY VARIES).
 211  K3 CLUTCH BACKING PLATE, 4.2 MM (.166") THICK.
 212  K3 CLUTCK BACKING PLATE SNAP RING, 2.5 MM (.099").

200

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212

Technical Service Information

200

206

208

ROUNDED EDGE

TOWARDS FRICTION

BACKING

PLATE

Figure 138

Figure 139

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)

Continued on Page 78

     9. Install the completed K3 balance piston and
             return spring as an assembly, as shown in
       Figure 138.
 10. Compress the balance piston and return spring
             and install the retaining snap ring, as shown in
       Figure 138.
 11. Install the K3 clutch plates beginning with a 
             steel plate and alternating with the friction
             plates, as shown in Figure 139, 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 K3 clutch backing plate, as shown
             in Figure 139, with the rounded edge facing
       the friction plate. 
 13. Install the K3 clutch backing plate snap ring,
       as shown in Figure 139.

42

COMPLETED K3 CLUTCH HOUSING

42

K3 Clutch Clearance Should Be

Approximately .010" Per Friction Plate

    72  NUMBER 1 THRUST WASHER (PL ASTIC).
 200  K3 CLUTCH HOUSING ASSEMBLY.

42

200

72

FITS

EITHER

WAY

FITS

EITHER

WAY

78

Technical Service Information

Figure 140

Figure 141

Figure 142

 14. Measure the K3 clutch clearance with a feeler
             gauge between the backing plate and snap ring,
       as shown in Figure 140.
       Note: There are no factory clutch clearance
       specifications available, but the clearances
             were the "traditional" .010" per friction plate
       through-out this unit.

 15. K3 clutch clearance should be approximately 
             .010" per friction plate installed, as shown in
       Figure 140. 
 16. Turn the K3 clutch housing over and install the
             number 1 thrust washer, engaging the tabs of
             the washer in housing, as shown in Figure 141.
 17. Set the completed K3 clutch housing aside for
       the final assembly process  (See Figure 142).

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING (CONT'D)

   The next 2 components in "Component Rebuild" 
section have changes in the components, that are not 
interchangeable, and related to whether you have a 
"2-Port" or a "3-Port" torque converter.  This 
requires an understanding of how each of these 
converters operate hydraulically and the description 
begins on Page 79, along with the dimensional 
differences in the affected parts.

Component Rebuild Section

Continues on Page 82

CAUTION!