Volkswagen Workshop Service and Repair Manuals

Dismantling planetary gearbox

Special tools, testers and auxiliary items

• ◆ Support clamp - VW 313
• ◆ Holding plate - VW 309
• ◆ Gearbox support - VW 353
• ◆ 2 M8 bolts
• ◆ 2 M10 bolts with nuts
• ◆ Drip tray

• ‒ Take out torque converter.
• ‒ → Secure gearbox to assembly support with bolts -1- and -2-.
• ‒ Seal ATF cooler connections.

• ‒ Place container under the gearbox.

• ‒ → Remove sealing plug -1- and ATF overflow pipe -2-.
• ‒ Drain ATF.

•      3 -     Sealing plug
•      4 -     Cap

• ‒ → Remove gearbox housing cover with gasket (arrow).

• ‒ Remove sump.
• ‒ Remove ATF screen.
• ‒ → Remove valve body with conductor strip.

• ‒ → Take out sealing plugs for -B1-.

• ‒ → Remove ATF pump bolts (arrows).

• ‒ → Screw bolts -A- (M8) into the tapped holes of ATF pump.
• ‒ Press ATF pump off gearbox by turning the bolts -A- evenly.

• ‒ → Take out all clutches with supporting tube, -B2- plates, springs and spring caps together.

On gearboxes from gearbox build date 14 04 7 the clutches -K1- and -K3- are pressed together.

Clutch -K1- must only be pressed off -K3- if one of the clutches is to be dismantled or renewed.

Pressing -K1- off -K3- .

• ‒ → Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft.

• ‒ → Loosen small input shaft bolt -arrow-.
• ‒ Remove small input shaft bolt, washer and shim.

• Planet carrier axial needle bearing remains in gearbox/input gear.

• ‒ Pull out small input shaft.

• ‒ → Pull out large input shaft (arrow).

• ‒ → Pull out large sun gear (arrow).

• ‒ Remove gearbox speed sender -G38-.

=> Repair group 01; Electrical/electronic components and fitting locations

• ‒ → Remove supporting tube circlip -a- and freewheel circlip -b-.
• ‒ Take freewheel out of gearbox housing by pulling on freewheel retaining wedge -arrow- with pliers.

• ‒ → Pull out planet carrier with dished spring.
• ‒ Remove reverse gear brake -B1- plates.

• ◆ It is not necessary to remove input gear to dismantle planetary gearbox. Removing and installing input gear => Page 39-8 .
• ◆ Assembling planetary gearbox => Page 37-91 .

Pressing clutch -K1- off -K3-

On gearboxes from gearbox build date 14 04 7 the clutches -K1- and -K3- are pressed together.

Clutch -K1- must only be pressed off -K3- if one of the clutches is to be dismantled or renewed.

• ‒ Ensure the tool press surface is flat and not damaged.

Pins in tube 3110 face towards plate VW 402.

• ‒ → Hold turbine shaft when pressing off.

Pressing clutch -K1- onto -K3-

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

• ‒ → Clip (2) axial needle bearing (1) with washer to 3rd and 4th gear clutch -K3-.

• ‒ Ensure the tool press surface is flat and not damaged.
• ‒ → Prepare -K1- and -K3- for pressing as illustrated.

• ‒ → Before pressing on, align VW 418 A centrally onto surface for axial needle bearing (this illustration shows -K3- from below).
• ‒ Align VW 418 A centrally.
• ‒ Press clutch -K1- on carefully until stop is perceptible.
• ‒ Do not exert further pressure onto clutches !

Assembling planetary gearbox

Special tools, testers and auxiliary items

• ◆ Approx. 3 ltr. VW ATF
• ◆ → Plug seal -arrow-

• ‒ → Fit O-ring into planet carrier.

After replacing planet carrier, adjust => Page 37-106 .

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

1 - Input gear is installed in gearbox housing => Page 37-68 .

2 - Axial needle bearing washer, insert smooth side into input gear.

3 - Axial needle bearing

4 - Axial needle bearing washer

5 - Install planet carrier with seal fitted

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

• ‒ Insert inner and outer -B1- plates.
• ‒ Insert pressure plate with flat side facing plates.

Thickness of pressure plate varies according to number of plates, replacement parts are allocated according to gearbox code letters.

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

When replacing

• ◆ Gearbox housing
• ◆ Freewheel
• ◆ Piston for reverse gear brake -B1-
• ◆ or plates

then adjust -B1-, => Page 37-114 .

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

• ‒ → Install circlip for freewheel -b- and circlip for supporting tube -a-.
• ‒ Insert circlip gaps over freewheel retaining wedge (arrow).
• ‒ Install gearbox speed sender -G38-.

=> Repair group 01; Electrical/electronic components and fitting locations

• ‒ Perform check measurement of -B1-
  => Page 37-120

• ‒ → Insert components into gearbox housing starting with the large sun wheel down to small input shaft.

1 - Large sun wheel

2 - Needle bearing washer

• (collar faces to large sun wheel)

3 - Axial needle bearing

4 - Large input shaft

5 - Axial needle bearing

6 - Needle bearing

7 - Small input shaft

• ‒ → Installing small drive shaft bolt -1- with washer -2- and shim -3-,
       Tightening torque 30 Nm.

• ◆ Insert shim -3- onto small input shaft shoulder (arrow).
• ◆ Determining shim thickness => adjusting planet carrier, Page 37-106 .

• ‒ Perform planet carrier check measurement
  => Page 37-113 .

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

On gearboxes from gearbox build date 14 04 7 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 clutch -K1- onto -K3- by hand.

• ‒ → If the splines -arrow 1- are visible in the -K1- hub, then both clutches must be pressed together first => Page 37-89 .

After pressing clutches together they can only be inserted into the gearbox together.

Resistance of O-ring is overcome when connecting together (by hand!)

→ If -K1- splines -arrow 1- are not visible.

• ‒ Continue to assemble the gearbox.

• ‒ → Clip axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.

1 - Axial needle bearing with thrust washer

• Several versions of axial needle bearings must be moistened with ATF so that the bearing sticks to -K3- when installing. Fit bearing thrust washer onto -K3-.

2 - 3rd and 4th gear clutch -K3-

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

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

If -K1- and -K3- are pressed together, both clutches can only be inserted together.

• ‒ → Insert shims -arrow- in -K1-.

• ◆ Remeasure shim when replacing -K1-, -K2- or ATF pump => adjusting clutch play between -K1- and -K2-, Page 37-121 .
• ◆ 1 or 2 shims can be installed.

• ‒ → Insert reverse gear clutch -K2-.
• ‒ Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel wedge.

• ‒ → Install -B2- plates as follows:
• ‒ First insert a 3 mm thick outer plate.
• ‒ Insert three spring caps in outer plate.
• ‒ Insert compression springs (arrows).
• ‒ Insert all, but the last outer plate
• ‒ Insert three spring caps onto compression springs.

Only on gearboxes with installed corrugated spring washer is the brake clearance -B2- determined by the last outer plate thickness. Determining thickness of plate is described on => Page 37-138 .

• ‒ Insert last -measured- outer plate.
• ‒ Install corrugated washer

→ On all other gearboxes (with retaining ring -b-) the last outer plate is always 3 mm thick. The clearance of brake -B2- is determined by a shim -a-, on which the retaining ring -b- seats. A corrugated spring washer is not present.

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

Determine shim => Page 37-128 .

• ‒ Install shim.
• ‒ Insert retaining ring -b- onto shim. Smooth side facing shim.

When replacing

• ◆ the gearbox housing
• ◆ Supporting tube
• ◆ the ATF pump
• ◆ corrugated spring washer
• ◆ retaining ring
• ◆ or the plates

then the 2nd and 4th gear brakes -B2- are to be adjusted

=> from page 37-128 .

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

• ‒ Install ATF pump seal.
• ‒ Fit O-ring on ATF pump..
• ‒ → Install ATF pump.
• ‒ Tighten bolts evenly, crosswise.

Ensure that the O-ring is not damaged.

Tightening torque: 8 Nm.

• ‒ Then turn bolts 90 ° further.

• Turning further can be done in several stages.

• ‒ Carry out check measurement of clutch play => Page 37-127 .
• ‒ → Insert sealing plugs with O-rings.

• Installation position: Lug engages in oil channel.

• ‒ Install valve body with conductor strip => from Page 38-20 .
• ‒ Install sump => from Page 38-20 .

• ‒ → Install cover (arrow) with gasket and spacer bushes.

Tightening torque: 8 Nm.

• ‒ → Screw in ATF overflow pipe -1- and sealing plug -2- with new seal hand tight.
• ‒ Install torque converter.
• ‒ Install gearbox => Page 37-39 .
• ‒ Fill with 3 litres of ATF => Page 37-55 .