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 tool

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

The catalogue is also available as a CD-ROM, which can be ordered as normal from Bertelsmann.

Gearbox

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

• ◆ → For gearbox repairs, an exchange component is available for the shift elements, which is often more cost effective.

=> Binder: Special information; Transmission; No.10

• ◆ Before installing the torque converter, observe sleeve bearing in turbine shaft .

• ◆ 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.

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.

Bearings

• ◆ Taper roller bearings are allocated in the parts catalogue according to gearbox build date and code letters.
• ◆ Always replace taper roller bearings which are mounted on a shaft together and use bearings from a single manufacturer.
• ◆ 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.

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.

Inner plates

• ◆ → Place new inner plates in 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.

Self-diagnosis

• ◆ Before repair work is carried out on the automatic gearbox, the cause of the fault should be determined as precisely as possible with the aid of Repair Group 01, Self-diagnosis.

=> Repair group 01