Skoda Workshop Service and Repair Manuals

Disassembling and assembling planetary gear Special tools and workshop equipment required t  Pressure plate -MP3-407 (VW 402)- t  Thrust piece -MP3-408 (VW 412)- t  Pipe section -MP3-409 (VW 418 A)- t  Pipe section -MP3-450 (VW 415 A)- t  Assembly ring -MP3-491 (3267)- t  Gearbox mount -MP3-501- t  Pipe section -3110- t  Adjusting device -3459- t  Assembly stand -MP9-101- t  Catch pan t  Locking agent -AMV 185 101 A1- Disassembling planetary gear –  Position the catch pan under the gearbox.

–  Remove screw plug -2- and ATF overflow tube -1-. –  Drain the ATF. –  Shut off the connections of the ATF-radiator. –  Remove torque converter → Chapter.

–  Attach gearbox to assembly stand -MP9-101--arrows-. Pay attention to note.   WARNING The center of gravity of the gearbox is outside the turning center at the tensioning block. For turning the gearbox, a second mechanic must hold the gearbox housing in order to avoid a back-swing.   Note Before fastening the gearbox for the first time, the gearbox holder must be reworked in accordance with the dimensions stated below.

–  Attach additional hole to gearbox holder.

-A-	= 55 mm
-B-	= 96 mm
Ø -C-	= 12 mm

Note

The gearbox can also be attached to the gearbox mount -T30109 (VW 353)- in combination with the retaining plate -T30108-, screws -1- and -2-.

–  Remove the cover with the seal -arrow- for the gearbox housing. –  Removing the oil pan. –  Remove ATF strainer.

–  Remove slide valve body with conductor foil → Chapter.

–  Remove plug for -B1--arrow-.

–  Remove gearbox speed sender -G38--arrow-.   Note The plug and the gearbox speed sender -G38- must be removed, in order to avoid damaging these parts.

–  Remove the screws -arrows- from the ATF pump.

–  Screw bolts -A- (M8) into the threaded holes of the ATF pump. –  Press off ATF pump from the gearbox housing by uniformly screwing in the screws -A-.

–  If present, remove strainer.   Note The strainer is disposed in the return flow of the ATF radiator. It cannot be retrofitted in older gearboxes.

–  Grip turbine shaft and pull out together all the clutches with support pipe for -B2-, plates for -B2-, springs and helical springs -arrow-. On certain gearboxes, the clutches -K1- and -K3- can be pressed together. Only if one of the clutches must be disassembled or replaced it must be pressed off -K1- from the -K3-. press off -K1- from -K3- → Anchor. –  Engage parking position.

–  Insert the screwdriver through the hole of the “large sun gear” in order to slacken the “screw for the small drive shaft”.   Note If the parking position cannot be engaged, block the large drive shaft additionally with a second screwdriver.

–  Remove screw -arrow- with washer and adjusting washer for the “small drive shaft”.    Axial needle bearing for planet carrier remains in the gearbox/drive shaft. –  Pull out small drive shaft.

–  Remove large drive shaft -arrow-.

–  Remove large sun gear -arrow-. l  Before removing the free wheel the gearbox speed sender -G38- and the plug must be removed.

–  Remove circlip for support pipe -a- and circlip for free wheel -b-. –  Grip planet carrier inside and pull out together with free wheel and disc spring.   Note If necessary, pull the free wheel on the retaining wedge -arrow- out of the gearbox housing using pliers. –  Remove pressure plate, plates and adjusting washer (s) of the reverse gear - brake -B1-. –  Remove axial bearing and washers.   Note t  The drive gear must not be removed to disassemble the planetary gear. Removing and installing drive gear → Chapter. t  Assembling planetary gear → Anchor. Press off clutch -K1 - of -K3- On certain gearboxes, the clutches -K1- and -K3- can be pressed together. Only if one of the clutches must be disassembled or replaced it must be pressed off -K1- from the -K3-. –  Pay attention that the pressure surfaces of the tools are not damaged. The stud in the pipe section -3110- points to the pressure plate -MP3-407 (VW 402)-.

–  Hold the turbine shaft when removing. Press clutch -K1 - on -K3-

–  Position new O-ring in the groove of the turbine shaft -arrow-. –  Moisten O-ring with ATF.

–  Position axial needle bearing with washer -1- on the 3rd and 4th gear-clutch -K3--2-. –  Moisten the washer of the axial needle bearing with ATF, so that the bearing adheres on the -K3- when installing. –  Pay attention that the pressure surfaces of the tools are not damaged.

–  Prepare -K1- and -K3- for pressing as shown here.

–  Align in the centre before pressing the pipe section -MP3-409 (VW 418 A)- on the surface of the axial needle bearing (this picture shows the -K3- from below). –  Carefully press on the clutch -K1- up to the tangible stop. –  Do not exert any further pressure forces on the clutches! Assembling planetary gear   Note For carrying out the repair of the automatic gearbox, an exchange component is available → Chapter. The gearbox identification characters are assigned to it → Electronic Catalogue of Original Parts.

–  Insert new O-ring -arrow- in the planet carrier.   Note Adjust planet carrier when replacing the planet carrier → Chapter.

–  Insert axial needle bearing with washers and planet carrier in the drive gear. 1 -  Drive wheel, is installed in the gearbox housing → Chapter 2 -  Washer for axial needle bearing, insert smooth side into the drive gear. 3 -  Axial needle bearing 4 -  Washer for axial needle bearing 5 -  Install planet carrier with newly installed O-ring

–  Insert washer and axial needle bearing on the “small sun gear” in the planet carrier. –  Align washer and axial needle bearing in the centre on the “small sun gear”.   Note t  When replacing the: t  Gearbox housing t  Free wheel t  Piston for reverse gear - brake -B1- t  or the plates t  the -B1- must be adjusted → Chapter. –  Insert adjusting washer(s). –  Insert inner and outer plates of -B1-. –  Insert pressure plate with the flat side to the plates. The thickness of the pressure plate differs depending on the number of plates and is assigned to gearbox identification characters as a spare part.

–  Insert disc spring with the curved side to the free wheel.

–  Preload the rollers of the free wheel with assembly ring -MP3-491 (3267)- and insert free wheel.

–  Install circlip for free wheel -b- and circlip for support pipe -a-. –  Openings of the circlips point to the retaining wedge -arrow- of the free wheel.

–  Install gearbox speed sender -G38--arrow-. –  Carry out control measurement -B1- → Chapter.

–  Insert parts in the gearbox housing starting with the large sun gear up to the small drive shaft. 1 -  Sun gear, large 2 -  Washer for axial needle bearing (collar points to the large sun gear) 3 -  Axial needle bearing 4 -  Drive shaft, large 5 -  Axial needle bearing 6 -  Needle bearing 7 -  Drive shaft, small

–  Install screw for small drive shaft -1- with washer -2- and adjusting washer -3-, tightening torque 30 Nm.   Note t  Place adjusting washer -3- on the collar of the small drive shaft -arrow-. t  Determine thickness of the adjusting washer → Chapter. –  Carry out control measurement → Anchor.

–  Moisten new O-ring with ATF. –  Position O-ring in the groove of the turbine shaft -arrow-.   Note On certain gearboxes, the clutches -K1- and -K3- must be pressed together before installing. –  Check whether the clutch -K1- can be fitted completely onto the serration of the turbine shaft of “K3”. –  Position the clutch -K1- onto -K3- by hand.

l  If the serration -arrow 1- is visible in the hub -K1-, both clutches must be pressed together → Anchor.

l  If the resistance of the O-ring is overcome, when fitting together (by hand !), the serration -arrow 1- of the -K1- is no longer visible. It is no longer necessary to press together the clutches. –  Then the gearbox can be further assembled.

–  Position axial needle bearing with washer -1- on the 3rd and 4th gear-clutch -K3--2-. –  Moisten the washer of the axial needle bearing with ATF, so that the bearing adheres on the -K3- when installing.

–  Check fitting of the piston rings on the -K3-. –  Make sure that the joints of the piston rings interlock with each other.

–  1. insert up to 3rd gear - clutch -K1- with 3rd and 4th gear - clutch -K3-.   Note 1. turn when inserting up to 3rd gear - clutch -K1- with 3rd and 4th gear - clutch -K3- until all the plates are in mesh.

–  Place adjusting washers -arrow- in -K1-.   Note t  The adjusting washer must be newly measured when replacing -K1-, -K2- the small drive shaft on the ATF pump, adjust ⇒ clutch clearance between -K1- and -K2-, → Chapter. t  Up to 3 adjusting washers can be installed.

–  Insert reverse gear-clutch -K2-.   Note Turn reverse gear clutch -K2- when inserting, until all the plates are in mesh. –  Insert the support pipe for the plate package -B2- in such a way that the groove of the support pipe grips into the wedge of the free wheel.   Note t  When replacing the: t  Gearbox housing t  Support pipe t  the ATF pump t  of the retaining ring or the wave spring washer t  or the plates t  if the 2nd and 4th gear brake -B2- must be adjusted → Chapter. These components are assigned to the gearbox identification characters as a spare part.

There are two versions of the brake -B2-: A -  Brake with wave spring washer B -  Brake with retaining ring

–  Install the plates -B2- as follows: –  First insert 3 mm thick outer plate. –  Position three helical springs in the outer plate. –  Insert pressure springs -arrows-. –  Insert all the plates up to the last outer plate. –  Position three helical springs on the pressure springs. Only on gearboxes with installed wave spring washer, the thickness of the last outer plate determines the play of the brake -B2 -. How to determine the thickness of this plate is described on → Chapter. –  Insert last - measured - outer plate. –  If present: insert wave spring washer.

On all other gearboxes (with retaining ring -b-) the last outer plate is always 3 mm thick. The play of the brake -B2- is determined by the adjusting washer -a-, on which the retaining ring -b- is fitted. A wave spring washer is then not available. –  Insert last outer plate - 3 mm thick. Determine adjusting washer → Chapter. –  Insert adjusting washer. –  Place retaining ring -b- on the adjusting washer. Smooth side to the washer.

–  If present, clean strainer and install.   Note The strainer is disposed in the return flow of the ATF radiator. It cannot be retrofitted in older gearboxes. –  Insert gasket for ATF pump, observe the position of the holes. –  Slightly moisten new O-ring with ATF and place on ATF pump.   Note Pay attention to correct fitting of piston rings.

–  Insert ATF pump and press by hand up to the stop. –  Subsequently, tighten the screws crosswise with 8 Nm.   Note Thus the O-ring must not be damaged. –  Subsequently torque the screws a further 90°. Tightening by 90° may occur in successive stages. –  Carry out control measurement of the clutch clearance → Chapter.

–  Insert plug -arrow- with new O-rings. l  Fitting position: peg -arrow- grips into the oil duct. –  Install slide valve body with conductor foil and oil pan → Chapter.

–  Install cover -arrow- with gasket and spacer bushes.    Tightening torque 8 Nm.

–  Install ATF overflow tube -1- (2 Nm) and screw plug -2- (15 Nm) with new gasket ring. –  Install torque converter → Chapter, to do so pay attention to the assignment → Chapter. –  Installing the gearbox → Chapter. –  Top up with ATF and inspect ATF level → Chapter.