Automatic gearbox 099 four-wheel drive: Technical data

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful gearbox repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Workshop Manual, are summarized here. They apply to this Workshop Manual.

Special tool

A summary of the special tools used in the Workshop manual precedes each repair procedure and can be found in "Special tools/Workshop equipment" binder.

Gearbox

When an automatic gearbox is exchanged, the VW ATF in the planetary gearbox page => 00-7.

• ◆ When installing gearbox, ensure that the dowel sleeves are fitted correctly.

Gaskets, oil seals

• ◆ → Radial shaft seals: Pack space between sealing lips with grease before installing.

• ◆ Always fit new O-rings.

• ◆ After installing, check ATF level in planetary gearbox or gear oil in final drive, adjust to correct level if necessary.

Locking elements

• ◆ Do not overstretch circlips; replace if necessary.
• ◆ Circlips must be properly seated in the grooves.

• ◆ → Renew spring pins
  Installation position: Slot longitudinal to line of force.

Nuts, bolts

• ◆ Nuts and bolts for attaching covers and housings must be slackened and tightened crosswise.
• ◆ Do not distort particularly sensitive parts, e.g. valve chest, and loosen or tighten diagonally in stages.
• ◆ The tightening torques stated apply to unoiled nuts and bolts.
• ◆ Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Then insert bolts with AMV 185 100 A1.
• ◆ Always renew self-locking nuts.

Bearings

• ◆ Install new tapered roller bearings as they are delivered without additional lubrication.
• ◆ Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.
• ◆ Heat the inner races of taper roller bearings to approx. 100 °C before inserting.
• ◆ Do not interchange the inner and outer races of same size bearings.
• ◆ Always replace taper roller bearings which are mounted on a shaft together and use bearings from a single manufacturer.

Shims

• ◆ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
• ◆ Check for signs of burr and damage. Install only shims which are in perfect condition.

Inner plates

• ◆ Place new inner plates in VW ATF fluid for 15 minutes before installing.

Valve chest

• ◆ Replace the valve chest if any of the selector elements are scorched.

Clutches

• ◆ Clutches K1, K2 and K3 should be dismantled only for cleaning. If parts are defective, replace clutch.
  Allocate clutches according to gearbox code letters.

Exchange component

• ◆ The exchange component includes all gear shift elements and the valve chest. It is allocated to the gearbox according to its code letters and may be ordered from the parts division.

Self-diagnosis

• ◆ Before performing repairs to the automatic gearbox, determine the cause of the fault as precisely as possible with the aid of Repair Group 01, Self-diagnosis.

The self-diagnosis is described in booklet "Alhambra 1996 ▸, Self-diagnosis for automatic gearbox 099 four-wheel drive".

=> Repair group 01