Volkswagen Workshop Service and Repair Manuals

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 tools

A summary of the special tools used in this Workshop manual can be found in Special tools/Workshop equipment binder.

Gearbox

When an automatic gearbox is exchanged, the ATF in the planetary gearbox page => 00-11.

• ◆ 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 gear oil level or ATF level; adjust to correct level, if necessary.

Locking elements

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

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 body, 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 needle bearings with the inscribed side (thicker sheet metal) facing the drift.
• ◆ Lubricate all bearings in gearbox with gear oil before installing. Oil with special care for measuring friction torque.
• ◆ 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 ATF fluid for 15 minutes before installing.

Valve body

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

Clutches

• ◆ Clutches K1, K2 and K3 should initially be dismantled only for cleaning. If parts are defective, replace clutch.
  Allocation of the clutches is via the gearbox code letters.

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.