Volkswagen 01M Transmission. Manual - part 117

243 ACCUMULATOR 2 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ).
244 ACCUMULATOR-2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ).
247 ACCUMULATOR-2 HOUSING ASSEMBLY.
248 ACCUMULATOR-2 ASSEMBLY SPACER PLATE.
376 K3 ACCUMULATOR REGULATOR VALVE BORE PLUG RETAINER.
377 K3 ACCUMULATOR REGULATOR VALVE BORE PLUG.
378 K3 ACCUMULATOR REGULATOR VALVE.
379 K3 ACCUMULATOR REGULATOR VALVE SPRING.
380 K1 ACCUMULATOR REGULATOR VALVE BORE PLUG RETAINER.
381 K1 ACCUMULATOR REGULATOR VALVE BORE PLUG.
382 K1 ACCUMULATOR REGULATOR VALVE.
383 K1 ACCUMULATOR REGULATOR VALVE SPRING.
384 B2 CLUTCH ACCUMULATOR PISTON.
385 B2 CLUTCH ACCUMULATOR PISTON OUTER SPRING.
386 B2 CLUTCH ACCUMULATOR PISTON INNER SPRING.
387 K3 CLUTCH ACCUMULATOR PISTON.
388 K3 CLUTCH ACCUMULATOR PISTON OUTER SPRING.
389 K3 CLUTCH ACCUMULATOR PISTON INNER SPRING.
390 K1 CLUTCH ACCUMULATOR PISTON.
391 K1 CLUTCH ACCUMULATOR PISTON SPRING.
392 K2 CLUTCH ACCUMULATOR PISTON.
393 K2 CLUTCH ACCUMULATOR PISTON OUTER SPRING.
394 K2 CLUTCH ACCUMULATOR PISTON INNER SPRING.
395 ACCUMULATOR PISTON AND SPRING RETAINER PLATE.
396 B1/K3 CHECK VALVE BORE PLUG RETAINER.
397 B1/K3 CHECK VALVE BORE PLUG.
398 B1/K3 CHECK VALVE (.250" STEEL BALL).
399 B1/K3 CHECK VALVE SEAT.
400 NUMBER 20 VALVE BORE PLUG RETAINER.
401 NUMBER 20 VALVE BORE PLUG.
402 NUMBER 20 VALVE.
403 NUMBER 20 VALVE SPRING.
404 MAIN LINE PRESSURE LIMIT VALVE.
405 MAIN LINE PRESSURE LIMIT VALVE SPRING.
406 CHECK VALVE (.392" DIAMETER).
407 CHECK VALVE SPRING.

376

243

384

387

388

389

390

391

392

393

394

395

396

400

401

402

403

404

405

406

407

397

398

399

368

385

386

243

244

380

381

382

383

377

247

248

247

378

379

"09G" ACCUMULATOR 2, EXPLODED VIEW

Figure 163

404

405

406

407

Technical Service Information

917

9170

T11

VALVE BODY ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

Continued on Page 100

35. Disassemble the accumulator 2 valve body and
place valves, springs and retainers on appropriate
trays exactly as they were removed, as shown in
Figure 163.
Note: All accumulator body pistons are the
same, but the accumulator springs should be
tagged for identification.
36. Clean all accumulator body parts thoroughly and
dry with compressed air.
37. Inspect all accumulator body parts thoroughly
for any wear and/or damage.
38. Assemble the valves, springs, bore plugs and
retainers exactly as shown in Figure 163, and
lube with proper ATF as they are installed.
Note: Use small amount of Trans-Jel® on the
flat retainers, to prevent them from falling out,
as all valves are not spring loaded.
39. Install the accumulator pistons and springs, as
shown in Figure 163, install the retainer plate
and "snug" the bolts at this time.
40. Turn the accumulator body over and install the
check valves, as shown in Figure 163.
41. With the small parts in place, install the spacer
plate onto the accumulator 2 body, as shown in
Figure 163.
42. Again using your hand as a clamp, hold spacer
plate against the accumulator body, turn the
assembly over and install it onto upper valve
body, as shown in Figure 164, and install proper
retaining bolts.
43. Torque all accumulator housing retaining bolts
on both accumulator housings as follows:
Retaining Bolts = 9 N·m (80 in.lb.).
Piston Retainer Bolts = 7 N·m (62 in.lb.).

Figure 164

Figure 165

917

243

247

243

244

243 ACCUMULATOR 2 HOUSING TO UPPER V.B. (64 MM LENGTH)(3 REQ).
244 ACCUMULATOR-2 HOUSING TO UPPER V.B. (52 MM LENGTH)(4 REQ).
247 ACCUMULATOR-2 HOUSING AND SPACER PLATE ASSEMBLY.

Technical Service Information

4051 - 1 - 1

03C2T02168

300 035H

09G

1004

472 AND 473

STILL STUCK

TO K2 HOUSING

512 STILL STUCK

TO BACK SIDE OF

K2 HOUSING

511

512

513

VALVE BODY ASSEMBLY (CONT'D)

COMPONENT REBUILD (CONT'D)

TRANSAXLE FINAL ASSEMBLY

Continued on Page 101

44. Turn the valve body assembly over, as shown in
Figure 166, and install the five lower valve body
to upper valve body retaining bolts.
45. Torque lower valve body to upper valve body
bolts to 9 N·m (80 in.lb.).
46. Set the completed valve body assembly aside
for the final assembly process.

100

Technical Service Information

240 LOWER V.B. TO ACCUMULATOR HOUSING 2 BOLT (70 MM LENGTH).
241 LOWER V.B. TO UPPER V.B. BOLT (39.5 MM LENGTH).
242 LOWER V.B. TO UPPER V.B. BOLT (28 MM LENGTH).

7CA3

3C0

706

240

241

242

Figure 166

Figure 167

472 NUMBER 9 THRUST BEARING.
473 NUMBER 9 "REAR" THRUST BEARING RACE.
511 K2 CLUTCH HOUSING ASSEMBLY.
512 NUMBER 11 THRUST BEARING.
513 NUMBER 11 THRUST BEARING RACE.

1. Position transaxle case as shown in Figure 167
and ensure number 11 thrust bearing race is still
installed in case.
Note: The B2 clutch piston, return spring and
snap ring should have been installed during
case component rebuild.
2. Ensure number 9 thrust bearing and race are still
in place and number 11 thrust bearing is still in
place on the K2 clutch housing and install the
completed K2 clutch housing into the transaxle
case, as shown in Figure 167.

3. Install the B2 clutch apply plate, as shown in
Figure 168, with the rounded edge facing up.
4. Install B2 clutch pack beginning with a friction
plate onto the apply plate and alternating with a
steel plate, as shown in Figure 168, until you
have installed the proper quantity, as quantity
may vary.
Note: All friction plates should be soaked in
proper fluid for 30 minutes before installing.
5. Install the B2 clutch backing plate on top of the
last friction, as shown in Figure 168, with the
rounded edge facing the friction.
Note: Notice the number stamped on top side
of backing plate, which is an indicator that it
is selective, but no selectives available as yet.
6. Install the B2 clutch backing plate snap ring, as
shown in Figure 168, with snap ring opening
toward the transfer bearing race.
Note: This snap ring is .064" in thickness.
7. Apply air pressure to the B2 clutch circuit, as
shown in Figure 169, to test the integrity and this
will also move the snap ring to top of the snap
ring groove in case, to prepare for measurement
of B2 clutch clearance.

101

Technical Service Information

4051 - 1 - 1

03C2T02168

300 035H

09G

1004

475

476

479

ROUNDED EDGE

FACING UP

ROUNDED EDGE

FACING DOWN

478

477

475 B2 CLUTCH BACKING PLATE SNAP RING (.064" THICKNESS).
476 B2 CLUTCH BACKING PLATE, STAMP "2", 3.6 MM (.142") THICK.
477 B2 CLUTCH FRICTION PLATES (QUANTITY MAY VARY).
478 B2 CLUTCH STEEL PLATES, 1.8 MM (.071") (QTY MAY VARY).
479 B2 CLUTCH APPLY PLATE, 3.0 MM (.119") THICK.

Continued on Page 102

Figure 168

Figure 169

ID STAMP

AD I

N U S

B2 CASE PASSAGE

TRANSAXLE FINAL ASSEMBLY (CONT'D)

Content .. 115 116 117 118 ..