Volkswagen 01M Transmission. Manual - part 110

102

101 K3 CLUTCH PISTON OUTER "O" RING SEAL.
102 K3 CLUTCH APPLY PISTON.
103 K3 CLUTCH PISTON INNER "O" RING SEAL.

100 K3 CLUTCH HOUSING ASSEMBLY.
102 K3 CLUTCH APPLY PISTON WITH "O" RING SEALS.
104 K3 CLUTCH PISTON RETURN SPRING ASSEMBLY.
105 K3 CLUTCH BALANCE PISTON.
106 K3 CLUTCH BALANCE PISTON SNAP RING.

101

100

102

104

105

106

103

COMPONENT REBUILD (CONT'D)

K3 CLUTCH HOUSING ASSEMBLY (CONT'D)

4. Install new inner and outer "O" ring seals in
the grooves of the K3 clutch apply piston, as
shown in Figure 107.
5. Lubricate both seals with a small amount of
Trans-Jel® and install K3 clutch apply piston
into K3 housing, as shown in Figure 108.
6. Install the return spring assembly into the K3
clutch housing, as shown in Figure 108.
Note: Ensure springs are seated in cavitys of
the piston (See Figure 108).
7. Lube the balance piston seal with small amount
of Trans-Jel® and install the balance piston, as
shown in Figure 108.
8. Compress the balance piston and install the
snap ring, as shown in Figure 108.

Continued on Page 71

Figure 107

Figure 108

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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100 K3 CLUTCH HOUSING ASSEMBLY.
107 K3 CLUTCH STEEL PLATES (QUANTITY MAY VARY).
108 K3 CLUTCH FRICTION PLATES (QUANTITY MAY VARY).
109 K3 CLUTCH BACKING PLATE.
110 K3 CLUTCH BACKING PLATE SNAP RING (.064" THICK).

107

108

100

109

110

ID STAMP

Factory K3 Clutch Clearance

Was 0.66 MM (.026")

With 3 Frictions

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 109

Figure 110

K3 CLUTCH HOUSING ASSEMBLY (CONT'D)

9. Install K3 clutch pack beginning with a steel
plate and alternating with frictions, as shown in
Figure 109, until you have installed the proper
quantity, as the quantity may vary.
Note: All friction plates should be soaked in
proper fluid for 30 minutes before installing.

Component Rebuild

Continued on Page 72

10. Install the K3 clutch backing plate on top of
the last friction, as shown in Figure 109, with
step side facing up.
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.
11. Install the K3 clutch backing plate snap ring,
as shown in Figure 109.
Note: This snap ring is .064" thick.
12. Measure the K3 clutch clearance with a feeler
gauge between the backing plate and friction
plate, as shown in Figure 110.
Note: There are no factory clutch clearance
specifications available, but the clearances
were the "traditional" .010" per friction plate
through-out this unit. Refer to Figure 110
for K3 clutch clearance with 3 frictions.
13. Set the completed K3 clutch housing assembly
aside for the final assembly process.

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121

122

125

126

127

128

129

130

131

132

133

134

123

124

REAR VIEW

120 NUMBER 5 THRUST BEARING RACE.
121 K1 CLUTCH BACKING PLATE SNAP RING, 1.62MM (.064") THICK.
122 K1 CLUTCH BACKING PLATE.
123 K1 CLUTCH FRICTION PLATES (QUANTITY WILL VARY).
124 K1 CLUTCH STEEL PLATES (QUANTITY WILL VARY).
125 K1 CLUTCH BALANCE PISTON SNAP RING.
126 K1 CLUTCH BALANCE PISTON.
127 K1 CLUTCH APPLY PISTON RETURN SPRING ASSEMBLY.

128 K1 CLUTCH APPLY PISTON.
129 K1 CLUTCH INNER "O" RING SEAL.
130 K1 CLUTCH OUTER "O" RING SEAL.
131 K1 CLUTCH HOUSING ASSEMBLY.
132 NUMBER 6 THRUST BEARING.
133 NUMBER 6 THRUST BEARING RACE.
134 K3 CLUTCH HOUSING DRIVE HUB.

K1 CLUTCH HOUSING AND RELATED PARTS, EXPLODED VIEW

Figure 111

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

COMPONENT REBUILD (CONT'D)

K1 CLUTCH HOUSING ASSEMBLY

1. Disassemble the K1 clutch housing assembly
using Figure 111 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 wear and/or damage, replace as necessary.

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 73

120

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129 K1 CLUTCH INNER "O" RING SEAL.
130 K1 CLUTCH OUTER "O" RING SEAL.
131 K1 CLUTCH HOUSING ASSEMBLY.

131

130

129

134

133

132

REAR VIEW

132 NUMBER 6 THRUST BEARING.
133 NUMBER 6 THRUST BEARING RACE.
134 K3 CLUTCH HOUSING DRIVE HUB.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

K1 CLUTCH HOUSING ASSEMBLY (CONT'D)

4. Install the number 6 thrust bearing race into
the K3 clutch housing drive hub, as shown in
Figure 112.
5. Install the number 6 thrust bearing into the K3
clutch housing drive hub with needles facing
down, as shown in Figure 112.
6. Set the completed K3 clutch housing drive hub
assembly aside for the minute.

7. Install K1 clutch apply piston inner and outer
"O" ring seals into the grooves in K1 clutch
housing, as shown in Figure 113, and lube with
a small amount of Trans-Jel®.
8. The K1 clutch apply piston is inclined to rotate
in, and damage the K1 clutch housing.
Note: There has been a new K1 clutch apply
piston developed by "DB Automobile" that
eliminates the rotation of the piston and saves
the damaged K1 clutch housing.
The new design K1 clutch housing piston is
shown in Figure 114, and is available from
your after-market supplier.

Figure 112

Figure 113

Figure 114

COMPONENT REBUILD (CONT'D)

Original Equipment

K1 Clutch Apply Piston

Improved K1 Clutch

Apply Piston From

"DB Automobile"

Continued on Page 74

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Content .. 108 109 110 111 ..