Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 309 Holding plate
• ◆ VW 313 Support clamp
• ◆ VW 353 Gearbox support
• ◆ VW 540 Engine and gearbox support
• ◆ 3336 Gearbox lifting beam
• ◆ T 10003 Spanner for clamping bolt

• ◆ V.A.G 1332 Torque wrench

• ◆ V.A.G 1306 Drip tray
• ◆ 3 bolts M8 x 35
• ◆ Sealant D176 404 A2

Dismantling planetary gearbox

• ● Gearbox suspended on lifting beam 3336

• ‒ Place container under the gearbox.
• ‒ → Remove plug -1-.
• ‒ Remove plug -2- and ATF overflow pipe -3-.
• ‒ Drain ATF.

• ‒ Take out torque converter.
• ‒ → Unscrew nut -arrow A- for lever/selector shaft.
• ‒ Remove screws -arrow B- for multi-function switch from gearbox.
• ‒ Remove electrical connections and sender from gearbox => from page 37-11 .

• ‒ → Secure gearbox to engine/gearbox support VW 540 -arrows- and fit into support clamp VW 313.
• ‒ Remove lifting beam 3336.

• ‒ → Remove ATF cooler from gearbox -arrow-.

• ‒ → Remove sump.

Gearbox up to manufacture date 06.99

• ‒ → Remove ATF temperature sender -A-.
• ‒ Separate solenoid valve connector by pressing the tabs -1- and pulling off -2-.

The cable colours are the same as the relevant solenoid valve colours.

• ‒ → Remove only the bolts marked by the arrows to remove the valve chest.

When removing the valve chest the manual selector valve -1- remains in valve chest.

• ‒ Secure manual selector valve so that it cannot fall out.

Gearbox from manufacture date 07.99

• ‒ → Remove ATF temperature sender -1-.
• ‒ Separate connection -2-.
• ‒ Remove wiring from holder -3-.
• ‒ Remove only the bolts marked with arrows A,B,C to remove the valve chest (different lengths).

When removing the valve chest, the manual selector valve -4- remains in the valve chest.

• ‒ Secure manual selector valve so that it cannot fall out.

Continued for all gearboxes

• ‒ → Remove O-rings -A-.
• ‒ Unclip wire -arrows- and remove the solenoid valve wiring harness.

• ‒ → Remove left and right flange shafts -arrow-.
• ‒ Remove securing bolts (Qty. 20) for the torque converter housing.
• ‒ Take off torque converter housing.

• ‒ → Take differential -arrow A- off gearbox housing.
• ‒ Remove O-ring -arrow B- from gearbox housing.
• ‒ Remove O-ring -arrow C- form turbine shaft.

• ‒ → Remove ATF pump bolts (arrows).

• ‒ → Remove gasket -1- for ATF pump from flange/gearbox housing.
• ‒ Remove shim -2- from reverse gear clutch -K2-.

• ‒ → Loosen lock nut -1- on the brake band adjustment screw -2-.
• ‒ Unscrew adjustment screw.
• ‒ Remove brake band.

• ‒ → After removing brake band, secure against opening out with e.g. a locally manufactured wire hoop -A-.

• ‒ → Remove reverse gear clutch -1-.

• ‒ → Remove 1st to 3rd gear clutch -B- with axial needle bearing -A-.

• ‒ → Remove axial needle bearing -1- from input shaft -2-.
• ‒ Pull out input shaft.

• ‒ → Remove needle bearing -A- with large sun wheel -B-.

• ‒ → Remove pinion -1- from gearbox housing.

• ‒ Turn gearbox by 180°in support clamp VW 313.
• ‒ → Loosen bolts for cover diagonally and in stages.
• ‒ Remove gearbox housing cover.

• ‒ → Remove O-rings -arrows- from gearbox housing.
• ‒ Remove 3rd and 4th gear clutch -A- with needle bearing -B-.

• ‒ → Remove needle bearing -A- from planet carrier -B-.
• ‒ Pull out planet carrier.

Gearbox up to manufacture date 06.99

• ‒ → Remove circlip for annulus.
• ‒ Take annulus off input gear.

Continued for all gearboxes

• ‒ → Remove circlip for reverse gear brake -B1- using a screwdriver.
• ‒ Remove thrust washers, pressure plate, inner and outer plates from the reverse gear brake -B1-.

Gearbox up to manufacture date 06.99

• ‒ → Remove circlip -A- for free-wheel -B- using a screwdriver.
• ‒ Pull free-wheel out of gearbox housing together with thrust washers.

• ‒ → Bend down the tab of the locking plate for the clamping bolt -A- with a screwdriver.

• ‒ → Unscrew clamping bolt from gearbox housing.

• ‒ → Take the input gear out of the gearbox housing.

Gearbox from manufacture date 07.99

• ‒ → Bend down the tab of the locking plate for the clamping bolt -A- with a screwdriver.

• ‒ → Unscrew clamping bolt from gearbox housing.

• ‒ → Remove input gear -A- from gearbox housing.
• ‒ Remove circlip -B- for free-wheel -C- using a screwdriver.
• ‒ Pull free-wheel out of gearbox housing together with thrust washers.
• ‒ Remove input gear from annulus .

Assembling planetary gearbox up to manufacture date 06.99

Assembling planetary gearbox up to manufacture date 07.99 => page 37-135 .

Insert axial needle bearing in its fitted position

• ‒ → Insert input gear into the gearbox housing.

• ‒ Insert new locking plate with the lugs in the recesses in the gearbox housing.
• ‒ → Tighten clamping bolt to prescribed torque => page 37-101 .

•      1 -     V.A.G 1332

• ‒ Lock clamping bolt with locking plate.
• ‒ Install free-wheel complete with thrust washers.
• ‒ Ensure correct fitting position when inserting the free-wheel
• ‒ Secure free-wheel in position with circlip.

• ‒ → Fit annulus onto input gear.
• ‒ Fit circlip for annulus on input gear with a screwdriver.

• ‒ → Place axial needle bearing -A- in correct fitted position (blackened surface remains visible) on the planet carrier -B-.
• ‒ Insert planet carrier simultaneously in the annulus and free-wheel. When inserting into the free-wheel the planet carrier will turn anti-clockwise.
• ‒ Functional check of freewheel:

It should only be possible to turn the planet carrier anti-clockwise (free- wheel open).

• ‒ → Install -B1- plates as follows:
• ‒ First place a pressure plate -5- (always 4.4mm thick) onto the circlip -6-.
• ‒ Insert the -B1- inner plates -7- and outer plates -4-.
• ‒ Place on the thrust plate -3-.
• ‒ Insert dished springs -2- in correct installation position (larger diameter faces one another).
• ‒ Install circlip -1-.
• ‒ Perform measurement check of -B1-
  => Page 37-151

• ‒ → Inserting 3rd and 4th gear clutch -K3-.
• ‒ Place O rings -arrows- onto the gearbox housing.

• ‒ → Press the spring cage onto the guide pins of the -B1- piston.

There are four guide pins -A- which are thicker and hold the spring cage in place.

• ‒ Coat axial needle bearing -B- with ATF so that it remains in position when fitting the gearbox housing cover.

Fit axial needle bearing in correct position (blackened surface remains visible) on the cover.

• ‒ → Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
• ‒ Apply sealant D 176 404 A2 onto clean sealing surface of the cover. The sealant bead must be
• ‒ 3...4 mm thick.
• ‒ Install gearbox housing cover.

• ‒ → Tighten bolts evenly and in diagonal sequence to prescribed torque => page 37-95 .
• ‒ Turn gearbox through 180°.

• ‒ → Insert pinion shaft -1-.

• ‒ → Insert large sun wheel -B- in the gearbox housing.

Place roller bearing -A- in correct position (smooth surface remains visible) on the large sun wheel.

• ‒ → Insert input shaft -2- into large sun wheel.

Place axial needle bearing -1- in correct fitted position (blackened side remains visible) onto the input shaft.

• ‒ → Insert 1st to 3rd gear clutch -B-.

Place axial needle bearing -A- in correct fitted position (blackened surface remains visible) into the 1st to 3rd gear clutch.

If individual parts of the planetary gearbox have been replaced the axial needle bearing must be recalculated =>Adjusting clutch clearance, from page 37-155 .

• ‒ → Insert reverse gear clutch -1-.

• ‒ → Place shim -2- onto the reverse gear clutch -K1-.

If individual parts of the planetary gearbox have been replaced the size of the shim must be recalculated =>Adjusting clutch clearance, from page 37-155 .

• ‒ Fit gasket -1- for ATF pump.

• ‒ → Install brake band as follows:
• ‒ Fit new adjustment screw -2- with lock nut -1- in gearbox.

• Do not screw in as far as the coating part of the thread. The final tightening of the adjustment screw is not carried out until the ATF pump has been installed =>adjusting the brake band, Page37-154 .
• ‒ Install brake band -3-.

• ‒ Align ATF pump to gearbox housing. When inserting, take care with shim, gasket for ATF pump and ATF pump piston rings.

• ‒ → Tighten ATF pump bolts -arrows- to prescribed torque => page 37-99 .

• ‒ → Install differential -arrow A-.
• ‒ Place new O rings -arrow B- on gearbox housing and in turbine shaft -arrow C-.
• ‒ Apply sealant D 176 404 A2 to the clean sealing surface of the torque converter housing. The sealant bead must be
• ‒ 3...4 mm thick
• ‒ Place torque converter housing on the gearbox housing; when doing this take care with dowel and ATF pump O ring.

• ‒ → Tighten bolts for torque converter housing to 30 Nm.
• ‒ Install left and right-hand flanged shafts -arrow- and tighten bolts to prescribed torque => from page 39-1 .
• ‒ Install plug with wiring harness for the solenoid valves.

• ‒ → Insert new O rings -A- in the gearbox housing.

• ‒ → Fit valve chest so that the pin of the detent plate engages in the groove of the selector spool valve -1-.
• ‒ Tighten bolts -arrows- to prescribed torque => page 38-31 .

• ‒ → Install ATF temperature sender -A-.
• ‒ Attach connectors -arrows- for the solenoid valves.

The cable colours are the same as the relevant solenoid valve colours.

• ‒ Install ATF screen and tighten bolts to prescribed torque => page 38-33 .

Apply sealant D176 404 A2 as follows to the oil pan:

• ‒ → Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
• ‒ Apply sealant as shown to the clean sealing surface of the oil pan. The bead of sealing compound must be
• ‒ 3...4 mm thick
• ‒ and run on inside of bolt holes -arrows-.
• ‒ Install oil pan and tighten bolts to prescribed torque => page 38-33 .

• ‒ → Fit ATF cooler to gearbox -arrow-.
• ‒ Install torque converter => from Page 32-3 .
• ‒ Install gearbox => Page 37-64 .
• ‒ Fill with ATF then check ATF level and top-up => Page 37-81 .

Assembling planetary gearbox from manufacture date 07.99

Insert axial needle bearing in its fitted position

• ‒ → Assembling input gear and annulus.

• ‒ Ensure correct installation position when inserting the free-wheel .
• ‒ → Install free-wheel complete with thrust washers -C-.
• ‒ Secure free-wheel in position with circlip -B-.
• ‒ Insert input gear with annulus -A-.

• ‒ Insert new locking plate with the lugs in the recesses in the gearbox housing.
• ‒ → Tighten clamping bolt to prescribed torque => page 37-101 .

•      1 -     V.A.G 1332

• ‒ → Lock clamping bolt with locking plate.

• ‒ → Place axial needle bearing -A- in correct fitted position (blackened surface remains visible) on the planet carrier -B-.
• ‒ Insert planet carrier simultaneously in the annulus and free-wheel. When inserting into the free-wheel the planet carrier will turn anti-clockwise.
• ‒ Functional check of freewheel:

It should only be possible to turn the planet carrier anti-clockwise (free- wheel open).

• ‒ → Install -B1- plates as follows:
• ‒ First place a pressure plate -5- (always 4.4mm thick) onto the circlip -6-.
• ‒ Insert the -B1- inner plates -7- and outer plates -4-.
• ‒ Place on the thrust plate -3-.
• ‒ Insert dished springs -2- in correct installation position (larger diameter faces one another).
• ‒ Install circlip -1-.
• ‒ Perform measurement check of -B1-
  => Page 37-151

• ‒ → Inserting 3rd and 4th gear clutch -K3-.
• ‒ Place O rings -arrows- onto the gearbox housing.

• ‒ → Press the spring cage onto the guide pins of the -B1- piston.

There are four guide pins -A- which are thicker and hold the spring cage in place.

• ‒ Coat axial needle bearing -B- with ATF so that it remains in position when fitting the gearbox housing cover.

Fit axial needle bearing in correct position (blackened surface remains visible) on the cover.

• ‒ → Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
• ‒ Apply sealant D 176 404 A2 onto clean sealing surface of the cover. The sealant bead must be
• ‒ 3...4 mm thick.
• ‒ Install gearbox housing cover.

• ‒ → Tighten bolts evenly and in diagonal sequence to prescribed torque => page 37-95 .
• ‒ Turn gearbox through 180°.

• ‒ → Insert pinion shaft -1-.

• ‒ → Insert large sun wheel -B- in the gearbox housing.

Place roller bearing -A- in correct position (smooth surface remains visible) on the large sun wheel.

• ‒ → Insert input shaft -2- into large sun wheel.

Place axial needle bearing -1- in correct fitted position (blackened side remains visible) onto the input shaft.

• ‒ → Insert 1st to 3rd gear clutch -B-.

Place axial needle bearing -A- in correct fitted position (blackened surface remains visible) into the 1st to 3rd gear clutch.

If individual parts of the planetary gearbox have been replaced the axial needle bearing must be recalculated =>Adjusting clutch clearance, from page 37-155 .

• ‒ → Insert reverse gear clutch -1-.

Cut outs -A- must be placed over tabs -B-.

• ‒ → Place shim -2- onto the reverse gear clutch -K1-.

If individual parts of the planetary gearbox have been replaced the size of the shim must be recalculated =>Adjusting clutch clearance, from page 37-155 .

• ‒ Fit gasket -1- for ATF pump.

• ‒ → Install brake band as follows:
• ‒ Fit new adjustment screw -2- with lock nut -1- in gearbox.

• Do not screw in as far as the coating part of the thread. The final tightening of the adjustment screw is not carried out until the ATF pump has been installed =>adjusting the brake band, Page37-154 .
• ‒ Install brake band -3-.

• ‒ Align ATF pump to gearbox housing. When inserting, take care with shim, gasket for ATF pump and ATF pump piston rings.

• ‒ → Tighten ATF pump bolts -arrows- to prescribed torque => page 37-99 .

• ‒ → Install differential -arrow A-.
• ‒ Place new O rings -arrow B- on gearbox housing and in turbine shaft -arrow C-.
• ‒ Apply sealant D 176 404 A2 to the clean sealing surface of the torque converter housing. The sealant bead must be
• ‒ 3...4 mm thick
• ‒ Place torque converter housing on the gearbox housing; when doing this take care with dowel and ATF pump O ring.

• ‒ → Tighten bolts for torque converter housing to 30 Nm.
• ‒ Install left and right-hand flanged shafts -arrow- and tighten bolts to prescribed torque => from page 39-1 .
• ‒ Install plug with wiring harness for the solenoid valves.

• ‒ → Insert new O rings -A- in the gearbox housing.

• ‒ → Fit valve chest so that the pin of the detent plate engages in the groove of the selector spool valve -4-.
• ‒ Observe bolt length:

• A = M6 x 80 mm
• B = M6 x 68 mm
• C = M6 x 40 mm

• ‒ Tighten bolts to prescribed torque => page 38-31 .
• ‒ Attach solenoid valve connectors -2-.
• ‒ Clip wiring into holder -3-.
• ‒ Clip in ATF temperature sender -1-.
• ‒ Install ATF screen and tighten bolts to prescribed torque => page 38-33 .

Apply sealant D176 404 A2 as follows to the oil pan:

• ‒ → Cut off tube nozzle at forward marking (nozzle approx. 3 mm ø).
• ‒ Apply sealant as shown to the clean sealing surface of the oil pan. The bead of sealing compound must be
• ‒ 3...4 mm thick
• ‒ and run on inside of bolt holes -arrows-.
• ‒ Install oil pan and tighten bolts to prescribed torque => page 38-33 .

• ‒ → Fit ATF cooler to gearbox -arrow-.
• ‒ Install torque converter => from Page 32-3 .
• ‒ Install gearbox => Page 37-64 .
• ‒ Fill with ATF then check ATF level and top-up => Page 37-81 .