Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Thrust plate VW 402
• ◆ Press tool VW 412
• ◆ Tube VW 415 A
• ◆ Tube VW 418 A
• ◆ Drive sleeve 40-20
• ◆ Assembly ring 3267

Assembling planetary gearbox

• ‒ → Fit O-ring -arrow- into planet carrier.

Notes:

• ◆ Use all parts of the exchange component when installing; do not use old parts.
• ◆ The planet carrier should be adjusted after replacing either the planet carrier, the large sun gear, the large input shaft or the small input shaft.

• ‒ → Insert axial needle bearing with washers and planet carrier in the input gear.

•     1 -    Install planet carrier with O-ring fitted
•     2 -    Washer for axial needle bearing
•     3 -    Axial needle bearing
•     4 -    Washer for axial needle bearing; smooth side faces toward input gear
•     5 -    Input gear; is fitted in gearbox housing
  

Gearboxes with code letters DMU, DMV, DMX, EPT, EPU, EPV:

• ‒ → Inserting small sun gear with washer and axial needle bearing into planet carrier.

•     1 -    Axial needle bearing
•     2 -    Washer for axial needle bearing
•     3 -    Small sun gear
•     4 -    Planet carrier

• ‒ Centralize washer and axial needle bearing in small sun gear.

Gearboxes with other code letters:

• ‒ → Place washer -2- and axial needle bearing -1- on the "small sun gear" in the planet carrier -3-.
• ‒ Centralize washer and axial needle bearing in small sun gear.

All models

• ‒ Insert shim(s).
• ‒ Insert inner and outer -B1- plates.
• ‒ Insert pressure plate of -B1- with flat side facing plates.

Note:

Thickness of pressure plate varies according to number of plates The replacement pressure plate is assigned to the gearbox code letters.

• ‒ → Insert dished washer with convex side facing towards freewheel.

Note:

When replacing the following components, adjust the reverse gear brake -B1- => Page 37-141:

• ◆ Free wheel
• ◆ Piston for reverse gear brake -B1-
• ◆ Plates
• ◆ Gearbox housing

• ‒ → Preload freewheel rollers with assembly ring 3267 and insert free wheel.

• ‒ → Installation position of free wheel: The retaining wedge (arrow) must be seated in the machined groove on gearbox housing.
• ‒ Fit circlip -b- for free-wheel.
• ‒ Fit open ends of circlips facing toward retaining wedge (arrow) of free-wheel.
• ‒ Insert baffle block -2- in gearbox housing groove, where ATF breather drilling -1- is located.

• ‒ → Install circlip -a- for supporting tube for -B2- with open ends of circlip facing toward retaining wedge -arrow- of free wheel.
• ‒ Perform check measurement of -B1-.
• ‒ Install gearbox speed sender -G38.

• ‒ → Install the parts in the gearbox housing in the reverse order of the numbering:

• 1 - Small drive shaft
• 2 - Needle bearing
• 3 - Axial needle bearing
• 4 - Large drive shaft
• 5 - Axial needle bearing
• 6 - Washer for axial needle bearing
  (shoulder faces toward large sun gear)
• 7 - Large sun gear

• ‒ → Install bolt -1- for small drive shaft with washer -2- and shim -3-.
• ‒ Tighten bolt to 30 Nm.

Notes:

• ◆ Insert shim -3- onto small input shaft shoulder (arrow).
• ◆ Determining shim thickness => adjusting planet carrier, Page 37-133.

• ‒ Carry out planet carrier check measurement => Page 37-140.

• ‒ → Insert new O-ring in the recess in the turbine shaft (arrow).
• ‒ Moisten O-ring with ATF.

Note:

On some gearboxes the clutches -K1- and -K3- must be pressed together before installing.

• ‒ Check that clutch -K1- can be fitted completely onto turbine shaft splines of -K3-.
• ‒ Do this by fitting -K1- onto -K3- by hand.
• ‒ → If splines (arrow 1) are visible in hub of -K1-, the clutches must be pressed together => Page 37-130.

• ‒ → If the resistance of the O-ring is overcome when fitting the clutches together by hand, the splines -arrow 1 - of -K1 are no longer visible. In this case the clutches do not have to be pressed together.
• Continue to assemble the gearbox.

• ‒ → Fit axial needle bearing together with washer -1- onto 3rd and 4th gear clutch -K3- , -Item 2-.
• ‒ Installation position: bearing washer faces toward -K3-.

Notes:

• ◆ Lubricate axial bearing washer with ATF to make sure that it adheres to -K3-.
• ◆ Shown in illustration on clutches which were not pressed together.

• ‒ → Ensure piston rings seat correctly on -K3-.
• ‒ Ensure that the ends of the piston rings are hooked together.

• ‒ → Inserting 3rd and 4th gear clutch -K3-.

Note:

When installing, rotate 3rd and 4th gear clutch -K3- until all the plates have meshed.

• ‒ Fit seal -1- in the groove (arrow).
• ‒ Moisten O-ring with ATF.

• ‒ → Inserting 1st to 3rd gear clutch -K1-.

Note:

If clutches -K1- and K3- are pressed together, they can only be installed as one unit.

• ‒ → Insert shim(s) -arrow- in -K1-.

Notes:

• ◆ The shim thickness must be recalculated when replacing -K1-, -K2-, the small input shaft or the ATF pump, => Adjusting clutch play between -K1- and -K2-, Page 37-149.
• ◆ 1, 2 or 3 shims can be installed.

• ‒ → Insert reverse gear clutch -K2-.

Note:

When installing, rotate reverse gear clutch -K2- until all the plates have meshed.

• ‒ Insert supporting tube for plate set of 2nd and 4th gear brake -B2- so that recess on lower part of supporting tube engages in retaining wedge of free wheel.

Note:

When replacing the following components, adjust the 2nd and 4th gear brake -B2- :

• ◆ Gearbox housing
• ◆ Supporting tube
• ◆ ATF pump
• ◆ Corrugated spring washer
• ◆ Retaining ring
• ◆ Plates

These components are allocated as replacement parts according to gearbox code letters.

• ‒ → Install -B2- 2nd and 4th gear brake plates as follows:
• ‒ First insert a 3 mm thick outer plate.
• ‒ Fit three spring caps into the outer plate.
• ‒ Insert the compression springs (arrows).
• ‒ Insert all the plates with the exception of the last outer plate.
• ‒ Fit three spring caps onto compression springs.

There are two versions of brake -B2-:

•     A -    Brake with corrugated spring washer
•     B -    Brake with retaining ring

Gearboxes with a corrugated spring washer installed on the last outer plate of brake -B2-

(code letters => from Page 00-3):

Note:

On these gearboxes the play of brake -B2- is determined by the thickness of the last outer plate. Calculating thickness of last outer plate.

• ‒ Insert last (measured) outer plate.

Note:

If it is necessary to fit two outer plates because of the results of the measurement, these should be fitted together on the spring caps.

• ‒ Install corrugated washer

Gearboxes with a shim and a retaining ring installed in brake -B2- (code numbers => from Page 00-3):

Note:

→ On these gearboxes, the thickness of the last outer plate is always 3 mm. The play of brake -B2- is determined by shim -a- onto which retaining ring -b- is inserted.

• ‒ Insert last outer plate -3 mm thick-.
• ‒ Determine thickness of shim => Page 37-156 and insert.
• ‒ Fit retaining ring onto shim.
• ‒ Fitting position: smooth side facing shim

All models

• ‒ → Clean and install strainer if fitted.

Note:

The strainer is located in the return pipe of the ATF cooler. It cannot be retrofitted on earlier gearbox versions.

• ‒ Install ATF pump gasket, noting position of holes.
• ‒ Fit O-ring on ATF pump..

Note:

Ensure the piston rings are properly seated.

• ‒ → Install ATF pump so that holes for securing bolts are correctly positioned.
• ‒ Tighten bolts evenly, crosswise, to 8 Nm.

Note:

Ensure that the O-ring is not damaged.

• ‒ Then turn bolts 90 ° further.

• Turning further can be done in several stages.

• ‒ Carry out check measurement of clutch play => Page 37-155.

• ‒ → Drive in cover with drive sleeve 40-20.
• ‒ Install gearbox speed sender -G38 =>Page38-61.

• ‒ → Insert sealing plugs with O-rings.
• ‒ Installation position: lug -arrow- fits into oil passage.

• ‒ Install valve body with conductor strip => from Page 38-27.
• ‒ Install oil pan => from Page 38-27.
• ‒ Install torque converter=>from Page 32-3.
• ‒ Cleaning ATF lines and cooler => page 37-80.
• ‒ Install gearbox => Page 37-49.
• ‒ Fill up with ATF and check ATF level => Page 37-59.