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Volkswagen 01M Transmission. Manual - part 108

550

552

553

554

555

556

557

558

559

560

556

554

551

550 CONVERTER COVER ASSEMBLY.
551 RIGHT HAND AXLE SEAL.
552 TAPERED ROLLER BEARING RACE (FINAL DRIVE).
553 TAPERED ROLLER BEARING RACE (TRANSFER/PINION SHAFT).
554 OIL PIPE "O" RING SEALS (4 REQUIRED).
555 LOWER OIL PIPE ASSEMBLY.
556 RETAINING BOLTS WITH WASHER, 11MM LONG (8 REQUIRED).
557 FINAL DRIVE OIL BAFFLE.
558 CENTER OIL PIPE.
559 CENTER OIL PIPE RETAINING BRACKET.
560 UPPER OIL PIPE ASSEMBLY.

COMPONENT REBUILD

CONVERTER COVER ASSEMBLY

Figure 89

1. Disassemble the converter cover parts using
Figure 89 as a guide.
2. Clean all converter cover parts thoroughly and
dry with compressed air.
3. Inspect all converter cover parts thoroughly and
replace as necessary.

4. Install new "O" ring seals on the 2 large diameter
oil pipes, as shown in Figure 89, and lube with a
small amount of Trans-Jel®.
5. Install the two large diameter pipes, as shown in
Figure 89,and torque the four retaining bolts to
8 N·m (70 in.lb.).
6. Install the center oil pipe by pressing into place,
as shown in Figure 89, and torque the retaining
bolt to 8 N·m (70 in.lb.).
7. Install the final drive oil baffle, as shown in
Figure 89, and torque bolts to 8 N·m (70 in.lb.).
8. Install new right hand axle seal, as shown in
Figure 89, using the proper seal driver.
9. Lube the inside diameter of the axle seal with a
small amount of Trans-Jel.
10. Install new tapered roller bearing races as
necessary.
11. Set the completed converter cover assembly aside
for final transaxle assembly.

Component Rebuild

Continued on Page 63

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WARNING: At 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.

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4051 - 1 - 1

03C2T02168

300 035H

09G

1004

1. Clean all transaxle case parts thoroughly and dry
with compressed air.
2. Inspect all case parts thoroughly and replace as
necessary.

3. Inspect the steel sleeve in the rear of case very
closely, as shown in Figure 90.
Note: This sleeve contains sealing rings for the
K2 clutch and sleeve is prone to "spinning" on
the case, creating cross-leaks.
There is a replacement sleeve available from
Sonnax® under part number 15759-01K with
improved retention and includes installation
instructions for 09G, 09K, 09M.
4. Install two new sealing rings into the grooves in
the steel sleeve at rear of case (See Figure 90)
and lube with small amount of Trans-Jel®.
5. Install tapered roller bearing and roller bearing
race as necessary, as shown in Figure 91.
Note: Shims under the tapered roller bearing
and the roller bearing race are used to set the
pre-load for final drive and transfer/pinion
gear shaft, which should be 4 to 6 inch pounds
of rotating torque.
6. Install new inner and outer "O" ring seals into
B2 clutch piston grooves, as shown in Figure 92,
and lube with small amount of Trans-Jel.

Figure 91

561

562

563

564

561 TAPERED ROLLER BEARING (FINAL DRIVE).
562 ROLLER BEARING SHIM (SETS FINAL DRIVE PRE-LOAD).
563 TAPERED ROLLER BEARING RACE (TRANSFER/PINION GEAR).
564 BEARING RACE SHIM (SETS TRANSFER/PINION PRE-LOAD).

Figure 90

COMPONENT REBUILD (CONT'D)

TRANSAXLE CASE ASSEMBLY

WARNING: At 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.

482

483

484

Figure 92

482 B2 CLUTCH APPLY PISTON.
483 B2 CLUTCH APPLY PISTON INNER "O" RING SEAL.
484 B2 CLUTCH APPLY PISTON OUTER "O" RING SEAL.

Continued on Page 64

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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513

4051 - 1 - 1

03C2T02168

300 035H

09G

1004

482

482 B2 CLUTCH APPLY PISTON.

Figure 93

7. Lubricate the "O" ring seal surfaces of the case
with a liberal amount of Trans-Jel®.
8. Install the B2 clutch apply piston into the case,
as shown in Figure 93.
Note: This piston must be oriented properly as
it installs in one direction only. The piston tab
without spring seal must be installed into slot
as shown in Figure 93.
9. Use extra care installing this piston as the seal is
easily damaged during the install process.
10. Install the B2 clutch return spring assembly, as
shown in Figure 94.
Note: The return spring assembly must also be
oriented properly, as shown in Figure 94.
Ensure that each of the springs are properly
seated on the tabs and over the centering cones.

COMPONENT REBUILD (CONT'D)

TRANSAXLE CASE ASSEMBLY (CONT'D)

Figure 94

Component Rebuild

Continued on Page 65

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

4051 - 1 - 1

03C2T02168

300 035H

09G

1004

480

481

480 B2 CLUTCH RETURN SPRING SNAP RING (.048" THICKNESS).
481 B2 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.
513 NUMBER 11 THRUST BEARING RACE.

This tab "must"

be installed in

this slot.

This tab "must"

be installed in

this slot.

11. Compress the return spring and install the snap
ring, as shown in Figure 94, and ensure it is fully
seated in the case groove.
Note: This snap ring is .048" thick and the
opening goes toward the transfer gear.
12. Install the number 11 thrust bearing into rear of
case, as shown in Figure 94, and retain with a
small amount of Trans-Jel®.
Note: Ensure tabs are engaged in case slots.

13. Set transaxle case aside for the final assembly

process.

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OIL PUMP ASSEMBLY EXPLODED VIEW

58 OIL PUMP CONVERTER HUB SEAL.
59 OIL PUMP CONVERTER HUB BUSHING.
60 OIL PUMP TO CONVERTER COVER "O" RING SEAL .
61 OIL PUMP TO CONVERTER COVER SEAL .
62 OIL PUMP BODY.
63 OIL PUMP HOLLOW ALIGNMENT DOWELS (2 REQUIRED).
64 OIL PUMP OUTER GEAR, GEROTOR STYLE.
65 OIL PUMP INNER GEAR, GEROTOR STYLE.
66 OIL PUMP COVER AND STATOR SHAFT ASSEMBLY.

67 PUMP COVER RETAINING BOLTS & WASHERS (8 REQUIRED).
68 OIL PUMP COVER, BUTT-CUT, SEAL RINGS (2 REQUIRED).
69 B-1 CLUTCH PISTON OUTER "O" RING SEAL.
70 B-1 CLUTCH PISTON.
71 B-1 CLUTCH PISTON INNER "O" RING SEAL.
72 OIL PUMP COVER CAGED NEEDLE BEARING.
73 NUMBER 1 THRUST WASHER.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

COMPONENT REBUILD (CONT'D)

OIL PUMP ASSEMBLY

1. Disassemble the oil pump using Figure 95 as a
guide.
2. Clean all oil pump assembly parts thoroughly
and dry with compressed air.
3. Inspect all oil pump assembly parts thoroughly
and replace as necessary.

Figure 95

WARNING: At 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.

Continued on Page 66

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