Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ 3459

These adjustment procedures are only valid for gearboxes with a shim and retaining ring installed in brake -B2- (=> Items 11 and 12 ).

With these gearboxes the brake -B2- play is determined by the thickness of the shim.

On some gearboxes a corrugated spring washer is installed on the last outer plate instead of the shim and retaining ring.

The brake -B2- play is then determined by the thickness of the last outer plate.

Adjustment procedure for these gearboxes .

• ‒ To adjust, install components without shim (item 11 ), without last outer plate (item 10 ) and without spring caps (item 6 ).

• Gearbox housing
• Circlip
• ◆ For supporting tube
• Supporting tube -B2-
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Insert so that notch locates on freewheel wedge
• Outer plate -B2-
• ◆ 3 mm thick
• Spring cap
• ◆ Install after installing first outer plate (item 4 )

• Spring cap
• ◆ Do not install when adjusting -B2-
• ◆ Install before installing last outer plate
• Spring
• ◆ Spare part is allocated according to gearbox code letters
• Inner plate -B2-
• ◆ Quantity => from Page 00-5
• ◆ Spare part is allocated according to gearbox code letters
• Outer plate -B2-
• ◆ Always install 2 mm thick outer plates
• ◆ Quantity => from Page 00-5
• Outer plate -B2-
• ◆ 3 mm thick
• ◆ Do not install when adjusting -B2-

• Shim
• ◆ Do not install when adjusting -B2-
• Retaining ring
• ◆ Inserted with smooth side facing last inner plate (item 8 ) when adjusting -B2-.

Determining shim(s)

The thickness of the shim(s) is determined by gap x. For this the formula

→ Gap x = a - b - 2.65 mm

must be used. The measuring points are shown in the illustration to help understanding the formula. Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.

Determining dimension a => Page 37-133 .

Determining dimension b => Page 37-135 .

2.65 mm - The amount for settling is taken into account by force F.

1 - ATF pump

2 - Retaining ring

3 - Plates for -B2- without last outer plate

4 - Supporting tube

First outer plate -arrow- and last outer plate (do not install to measure!) are always 3 mm thick.

Calculating dimension "a":

Assemble planetary gearbox up to the last -B2- inner plate, => Page 37-91 . The last outer plate and shim are not installed.

• ‒ → Place retaining ring with smooth side onto last inner plate.
• ‒ Place 3459 onto retaining ring and turn so that the 3 clips align with the 3 holes for the ATF pump.
• ‒ Bolt 3459 to flange for ATF pump with 5 Nm.

The plate packet for -B2- is now pressed together for the measurements.

• ‒ → Measure from pump flange/gearbox housing -arrow- to 3459 with depth gauge.

Dimension a = Height of 3459 in mm - measured value

Example:

• ‒ Note calculated value a.
• ‒ Remove 3459.
• ‒ Remove retaining ring.

Calculating dimension "b":

• ‒ Push piston into ATF pump onto stop.
• ‒ Place paper gasket onto ATF Pump.

• ‒ → Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.

Example:

• ‒ Note calculated value b.

Gap x = a - b - 2.65 mm

Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm

• ‒ Determine size of shim(s) according to table:

Table of "Shims":

• ‒ Ascertain thickness of shim(s) according to table and determine Part No. from parts catalogue.

• In this example two shims must be installed (each 1mm thick).
• ‒ Insert three spring caps onto compression springs.

• ‒ Insert last outer plate -3 mm thick-.

• ‒ → Install determined shim(s) -a-.
• ‒ Place retaining ring -b- onto shim(s). Smooth side facing shim.
• ‒ Further installation instructions are described => from page 37-102 .

Adjusting 2nd and 4th gear brake -B2-

Special tools, testers and auxiliary items

• ◆ 3459

This adjustment instruction is only valid for gearboxes where a corrugated spring washer in brake -B2- on the last outer plate is installed (=> Items 10 and 11 ).

These gearboxes have the code letters:

CLB, DLL, CLK, DKS, CKX, DKR, CKZ, DAB, CKY, CLA

With these gearboxes the brake -B2- play is determined by the thickness of the last outer plate(s).

• ‒ To adjust, install components without corrugated washer (item 11 ), without last outer plate (item 10 ) and without spring caps (item 6 ).

• Gearbox housing

• Circlip
• ◆ For supporting tube
• Supporting tube -B2-
• ◆ Spare part is allocated according to gearbox code letters
• ◆ Insert so that notch locates on freewheel wedge
• Outer plate -B2-
• ◆ 3 mm thick
• Spring cap
• ◆ Install after installing first outer plate (item 4 )
• Spring cap
• ◆ Do not install when adjusting -B2-
• ◆ Install before installing last outer plate
• Spring
• ◆ Spare part is allocated according to gearbox code letters

• Inner plate -B2-
• ◆ Quantity => from Page 00-5
• ◆ Spare part is allocated according to gearbox code letters
• Outer plate -B2-
• ◆ Always install 2 mm thick outer plates
• ◆ Quantity => from Page 00-5
• Outer plate -B2-
• ◆ Do not install when adjusting -B2-
• ◆ To adjust; 2 outer plates can be installed.
• Corrugated washer
• ◆ Do not install when adjusting -B2-

Calculating thickness of last outer plate -A-

The thickness of the last outer plate(s) is determined by gap "x". For this the formula

→ Gap x = a - b - 3.6 mm

must be used. The illustration shows the assembled brake -B2- in the gearbox. Special tool 3459, which exerts a force on the pack of plates, is not illustrated.

Determining dimension b => Page 37-143 .

3.6 mm - This amount allows for the settling caused by the force exerted by special tool 3459.

First outer plate -arrow- is always 3 mm thick.

Calculating "a":

Assemble planetary gearbox up to the last inner plate of -B2-, Page 37-91 . The last outer plate, the last 3 spring caps and the corrugated spring washer are not installed.

• ‒ Place 3459 onto the last inner plate and turn so that the 3 clips align with the 3 holes for the ATF pump.
• ‒ Bolt 3459 to flange for ATF pump with 5 Nm.

The plate packet for -B2- is now pressed together for the measurements.

• ‒ → Measure from pump flange/gearbox housing -arrow- to 3459 with depth gauge.

Dimension a = Height of 3459 in mm - measured value

Example:

• ‒ Note calculated value a.
• ‒ Remove 3459.

Calculating dimension"b":

• ‒ Push piston into ATF pump onto stop.
• ‒ Place paper gasket onto ATF Pump.
• ‒ → Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.

Example:

• ‒ Note calculated value b.

Gap x = a - b - 3.6 mm

Gap x = 30.2 - 20.6 - 3.6 mm = 6.0 mm

• ‒ Determine thickness of outer plate(s) according to table:

Table of "plates":

• ‒ Ascertain thickness of outer plate(s) according to table and determine Part No. from parts catalogue.

• In this example two outer plates must be installed (each 2.25mm thick).
• ‒ Insert three spring caps onto compression springs.

• ‒ Install determined last outer plate(s).
• ‒ Install corrugated washer
• ‒ Further installation instructions are described => from page 37-103 .