VW/Audi 096, 097, 098, 01M, 01N, 01P Bushing Kit Forward Clutch ...
T r a n s m is s ion Part s Instructions
VW/Audi 096, 097, 098, 01M, 01N, 01P
Bushing Kit R
EQ
D
Part No.
TOOL
UIRE
119905-02K
• Forward Clutch Drum Bushing K1 • Shaft Bushing K1 (096, 097, 098 only) • Reverse Clutch Drum Bushing K2
Shaft Bushing (K1)
Forward Clutch Drum Bushing (K1)
Reverse Clutch Drum Bushing (K2)
Note: This kit fits VW Beetle, Cabrio, Golf, Jetta and Passat, ‘95-Later.
Forward Clutch Drum Tool
K1
Part No.
Forward Clutch Drum (K1) Tool
119905-TL1
Shaft Bushing Tool
K1
119905-TL5
Note: This tool is for 096, 097 & 098 only.
Part No.
119905-TL2
Reverse Clutch Drum (K2) Tool
Notes & Cautions • This kit does not require machining.
Part No.
Reverse Clutch Drum Tool
Shaft Bushing (K1) Tool
• Bushings usually have a chamfer on the O.D. leading and trailing edge; these should be cleaned up with a fine sandpaper, 400 grit or finer. The leading edge of the housing bore, where the bushing first makes contact, should also be cleaned off with 400 grit or finer sandpaper. Any nicks or surface irregularities within the housing bore should also be smoothed down with a fine sandpaper. Bushing should be installed dry, no lube. Any burrs trapped between the bushing O.D. and housing bore will create “high” spots that reduce the I.D. of the bushing, and make it less round. Following these instructions will greatly improve your chances for a successful installation. • T ight clearances may require hand honing of any high spots. Use a "spin test" to locate high spot witness marks.
1. Disassembly a. Remove the forward clutch drum (K1) bushing that supports the K2 clutch drum. K2
b. Remove the shaft (K1) bushing that supports the K3 shaft. Note: 096, 097, 098 applications only.
c. Remove the reverse clutch drum (K2) bushing that supports the pump stator. 2. Installation. a. Install the large diameter, forward clutch drum bushing 119905-01 (K1), using associated tool 119905-TL1. The depth should be .032"/.036" below the face of the bore. b. Install the small diameter, shaft bushing 119905-05 (K1), using shaft bushing tool 119905-TL5 (096, 097, 098 units only). The depth should be level with the bottom of the bore’s chamfer. c. Install the reverse clutch drum bushing 119905-02 (K2), using associated tool 119905-TL2. The depth should be .058"/.062" below the face of the bore.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
119905-02K-IN 06-25-13
VW/Audi 096, 097, 098, 01M, 01N, 01P
Bushing Kit R
EQ
D
Part No.
TOOL
UIRE
119905-02K
• Forward Clutch Drum Bushing K1 • Shaft Bushing K1 (096, 097, 098 only) • Reverse Clutch Drum Bushing K2
Shaft Bushing (K1)
Forward Clutch Drum Bushing (K1)
Reverse Clutch Drum Bushing (K2)
Note: This kit fits VW Beetle, Cabrio, Golf, Jetta and Passat, ‘95-Later.
Forward Clutch Drum Tool
K1
Part No.
Forward Clutch Drum (K1) Tool
119905-TL1
Shaft Bushing Tool
K1
119905-TL5
Note: This tool is for 096, 097 & 098 only.
Part No.
119905-TL2
Reverse Clutch Drum (K2) Tool
Notes & Cautions • This kit does not require machining.
Part No.
Reverse Clutch Drum Tool
Shaft Bushing (K1) Tool
• Bushings usually have a chamfer on the O.D. leading and trailing edge; these should be cleaned up with a fine sandpaper, 400 grit or finer. The leading edge of the housing bore, where the bushing first makes contact, should also be cleaned off with 400 grit or finer sandpaper. Any nicks or surface irregularities within the housing bore should also be smoothed down with a fine sandpaper. Bushing should be installed dry, no lube. Any burrs trapped between the bushing O.D. and housing bore will create “high” spots that reduce the I.D. of the bushing, and make it less round. Following these instructions will greatly improve your chances for a successful installation. • T ight clearances may require hand honing of any high spots. Use a "spin test" to locate high spot witness marks.
1. Disassembly a. Remove the forward clutch drum (K1) bushing that supports the K2 clutch drum. K2
b. Remove the shaft (K1) bushing that supports the K3 shaft. Note: 096, 097, 098 applications only.
c. Remove the reverse clutch drum (K2) bushing that supports the pump stator. 2. Installation. a. Install the large diameter, forward clutch drum bushing 119905-01 (K1), using associated tool 119905-TL1. The depth should be .032"/.036" below the face of the bore. b. Install the small diameter, shaft bushing 119905-05 (K1), using shaft bushing tool 119905-TL5 (096, 097, 098 units only). The depth should be level with the bottom of the bore’s chamfer. c. Install the reverse clutch drum bushing 119905-02 (K2), using associated tool 119905-TL2. The depth should be .058"/.062" below the face of the bore.
©2013 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
119905-02K-IN 06-25-13
