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

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

Gearbox

When an automatic gearbox is exchanged, the ATF is to be checked and topped up as necessary. Capacities and specifications =>page 00-18 .

• ◆ When installing gearbox, ensure that the dowel sleeves are fitted correctly.

Oil seals

• ◆ → Radial shaft seals: Pack space between sealing lips with grease before installing.
• ◆ Always fit new O-rings.

Sealant

• ◆ Thoroughly clean separating surfaces and apply sealant D176 404 A2.
• ◆ Note the use by date of the sealant.
• ◆ Join components together within 5 minutes of applying sealant.
• ◆ Allow sealant to dry for 30 minutes, then fill afterwards with ATF.

• ◆ After installing check ATF level, 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.

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 and bolts after removal.
• ◆ Always renew bolts, which must be tightened further at an angle.

Bearings

• ◆ Install bearings in gearbox with ATF. Oil with special care for measuring friction torque.
• ◆ Insert axial needle bearing to correct installation position =>Page 37-104 .
• ◆ 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.

Piston rings

• ◆ Do not overstretch when removing or installing.

Inner plates

• ◆ → Place new inner plates in ATF fluid for 15 minutes before installing.

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.

Clutches

• ◆ Clutches can be dismantled, allocate defective parts (e.g. outer and inner plates) according to gearbox code number.
• ◆ Moisten sealing lips and sealing rings with ATF before installing the piston.
• ◆ → It must be possible to turn the piston by hand in both directions (arrows) after it has been installed into clutches or brakes.
• ◆ If this is not the case, the sealing lips or sealing rings may catch or become damaged.
• ‒ If this defect occurs, remove piston.

• ‒ Check sealing lips or sealing rings for damage, renew if necessary.
• ‒ Install piston again and check.

Brakes

• ◆ Do not overstretch brake band -B2- using force.

→ Secure brake band, after removal with a locally manufactured wire clip -A- to stop it opening out.

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.

=> Self-diagnosis for automatic gearbox 001; Repair group 01; Function of self-diagnosis