Volkswagen 01M Transmission. Manual - part 64

417 B2 CLUTCH BACKING PLATE SNAP RING, 2.5 MM (.099") THK.
418 B2 BACKING PLATE, STAMPED "63", 6.32 MM (.248") THICK.
419 B2 CLUTCH FRICTION PLATE (QUANITY VARIES).
420 B2 CLUTCH STEEL PLATES, 1.82 MM (.072") THICK.
421 B2 APPLY PLATE, STAMPED "50", 5.05 MM (.199") THICK.

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417

418

419

420

421

Figure 204

Figure 203

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COMPLETED

REAR RING GEAR,

OUTPUT SHAFT AND

K2 CLUTCH HOUSING

ASSEMBLY

COMPLETED

REAR RING GEAR,

OUTPUT SHAFT AND

K2 CLUTCH HOUSING

ASSEMBLY

TRANSMISSION ASSEMBLY (CONT'D)

   5. Lubricate the output shaft seals and seal surface
           in case with small amount of Trans-Jel®, and
           install the completed rear ring gear, output shaft
           and K2 clutch housing, as shown in Figure 203.
   6. The entire B2 clutch pack must be temporarily
           installed, as shown in Figure 204, to verify the
  B2 clutch clearance.

Continued on Page 116

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Figure 205

Figure 206

TRANSMISSION ASSEMBLY (CONT'D)

Continued on Page 117

ROUNDED EDGE

TOWARDS FRICTION

ROUNDED EDGE

TOWARDS FRICTION

BACKING

PLATE

APPLY

PLATE

B2 CLUTCH STACK-UP

     7. Install the B2 clutch apply plate, as shown in
             Figure 204, with the "rounded" edge facing up
             towards the friction, as shown in Figure 205.
     8. Install B2 clutch plates beginning with a friction
             and alternating with the steel plates, as shown in
             Figure 204, until you have the proper amount
installed as quantity may vary.
Note: All friction plates should be soaked in
             proper fluid for 30 minutes before installing.
     9. Install the B2 clutch backing plate, as shown in
             Figure 204, with "rounded" edge facing down
             toward the last friction, as shown in Figure 205.
10. Install the B2 clutch backing plate snap ring, as
             shown in Figure 204, and ensure fully seated.
11. Measure the B2 clutch clearance using a feeler
             gauge between the backing plate and friction
plate, as shown in Figure 206.
Note: There are no factory clutch clearance
specifications available, but the clearances
             were the "traditional" .010" per friction plate
through-out this unit.
12. B2 clutch clearance should be approximately
           .010" per friction plate installed, as shown in
Figure 206.
13. After verification of the B2 clutch clearance,
remove the entire B2 clutch pack.

B2 Clutch Clearance Should Be

Approximately .010" Per Friction

Plate Installed

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* 20SGL

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408 F1 SPRAG OUTER RACE SNAP RING, 1.19 MM (.047") THICK.
409 F1 SPRAG INNER RACE SNAP RING, 1.19 MM (.047") THICK.
413 F1 SPRAG ASSEMBLY COMPLETE.

408

409

413

Figure 207

Figure 208

454

* 20SGL

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452

SPRAG RACE
SPACER AND

WAVE SPRING

SPRAG RACE
SPACER AND

WAVE SPRING

452 NUMBER 10 THRUST BEARING (INSIDE CARRIER).
453 COMPLETED REAR PL ANETARY CARRIER ASSEMBLY.
454 NUMBER 11 BEARING FRONT RACE (BACK OF CARRIER).

453

Continued on Page 118

14. Ensure that number 11 thrust bearing front race
             is still stuck to the back side of planetary carrier,
as shown in Figure 207.
15. Ensure that number 10 thrust bearing is installed
           inside of the rear planetary carrier, as shown in
  Figure 207.
16. Install completed rear planetary carrier into case,
           as shown in Figure 207, by rotating to engage the
           pinion gears into ring gear and rotate back and
           forth to engage each of the K2 friction plates on
           rear planetary carrier hub until fully seated.
17. Re-install the entire B2 clutch pack using steps
           7 thru 10 on Page 116.

TRANSMISSION ASSEMBLY (CONT'D)

18. Install completed F1 sprag assembly, as shown
in Figure 208.
Note: Lugs on outer race must engage slots in
             case and splines on inner race must engage the
splines on rear planetary carrier.
19. Install outer race to case snap ring, as shown in
             Figure 208, and ensure it is fully seated in case.
20. Install inner race to planetary carrier snap ring,
             as shown in Figure 208, and ensure it is fully
seated in planetary carrier.

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450

451

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

Figure 211

Figure 210

TRANSMISSION ASSEMBLY (CONT'D)

21. After installation and both snap rings are fully
             seated, planetary carrier and sprag inner race
             should freewheel in a clockwise direction, as
shown in Figure 209.
22. Ensure number 10 thrust bearing race is still
             stuck to bottom of small rear sun gear, as shown
             in Figure 210, and install sun gear into the rear
planetary carrier.
23. Install the number 9 thrust bearing race onto the
             rear planetary carrier, as shown in Figure 211.
24. Ensure number 9 thrust bearing is still stuck to
             back of large sun gear and shell, as shown in
             Figure 211, and install the large sun gear into
planetary carrier by rotating into position.

Planetary Carrier And Sprag Inner

Race Should Freewheel Clock-Wise

Figure 209

EWH

* 20SGL

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405

406

407

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

Continued on Page 119

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