Volkswagen Workshop Service and Repair Manuals

Dismantling → planetary gearbox

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Tube -VW 418 A-

t	Tube -3110-

t	Gearbox mounting support -3336-

t	Drip tray -V.A.G 1306-

t	Torque wrench -V.A.G 1331-

t	Assembly ring -3267-

–  Observe general repair instructions → Chapter. –  Drain → ATF. –  Take out → torque converter.

–  Secure gearbox to assembly stand with bolts -1- and -2-.

–  Remove cover with seal. –  Remove ATF pan → Chapter Remove → ATF strainer → Chapter.

–  Remove → valve body with conductor strip → Chapter. Remember: from outside to inside, diagonally.

–  Pull out plug for -B1-.

–  Remove gearbox speed sender -G38-.

–  Remove → ATF pump bolts -arrows-. –  Mark installation position of → ATF pump in gearbox housing.

–  Screw bolts -A- (M 8) into tapped holes of → ATF pump. –  Press → ATF pump off gearbox housing by evenly turning bolts -A- and remove.

–  Remove strainer if present. The strainer is located in return line from → ATF cooler.

–  Pull out all → clutches with support tube, -B2- plates, springs and spring caps together on turbine shaft upwards -arrow-. → Clutches -K1- and -K3- may be pressed together in some gearboxes. Clutch -K1- must be pressed off -K3- only if one of the → clutches is to be dismantled or renewed. Pressing -K1- off -K3- → Chapter. –  Engage → parking lock.

–  Insert screwdriver through holes of “large sun gear” to loosen and tighten “bolt for small input shaft”. –  If → parking lock cannot be engaged, also block large input shaft with a second screwdriver.

–  Remove bolt for “small input shaft”. –  Remove bolt, washer and shim for “small input shaft”. Needle thrust bearing for planet carrier remains in gearbox input gear. –  Remove screwdriver. –  Pull out small input shaft.

–  Pull out large input shaft -arrow-.

–  Pull out large sun gear -arrow-.

–  Remove retaining ring -a- for support tube of -B2-. –  Remove retaining ring -b- for freewheel. –  Take freewheel out of gearbox housing by pulling on freewheel retaining wedge -arrow- with pliers.

–  Pull out planet carrier together with dished washer. –  Remove pressure plate, plates and shim(s) of reverse gear brake -B1-. It is not necessary to remove input gear in order to dismantle → planetary gearbox. Removing and installing input gear → Chapter. Assembling → planetary gearbox → Chapter.