Disassembling and Assembling
Special Tools And Equipment
- VW 309 Support fixture
- VW 313 Support clamp
- VW 353 Transmission support
- VW 402 Press plate
- VW 412 Press tool
- VW 415 A sleeve
- VW 418 A sleeve
- 3110 Sleeve
- 3267 Assembly ring
- 3336 Transmission lifting beam
- VAG 1331 Torque wrench or equivalent
Transmission, Disassembling
- Transmission is attached to transmission support device 3336
- Place drain pan under transmission.
- Remove sealing plug -1- and ATF overflow line -2-,
- Drain ATF
3. Sealing plug
4. Cap
- Seal ATF cooler connections.
- Remove torque converter.
- Secure transmission to assembly support with bolts -1-and -2- (M10).
- Remove transmission support device 3336.
- Remove transmission housing cover with gasket -arrow-.
- Remove oil pan.
- Remove ATF screen.
- Remove valve body with conductor strip. Refer to Valve Body; Service and Repair.
- Remove sealing plugs for -B1- -arrow-.
- Remove ATF pump bolts (arrows).
- Install bolts -A- (M8) in threaded holes of ATF pump.
- Press ATF pump off transmission by turning bolts -A- evenly.
- Remove all clutches with support sleeve, -B2- plates, springs and spring caps together.
The clutches -K1- and -K3- are pressed together.
Press clutch -K1- off -K3- only if one of the clutches must be be disassembled or replaced.
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 transmission/input gear.
- Remove small input shaft.
- Remove large input shaft -arrow-.
- Remove large sun gear -arrow-.
- Remove Transmission Vehicle Speed Sensor (VSS) -G38-.
- Remove support tube circlip -a- and free wheel circlip -b-.
- Remove freewheel from transmission housing by pulling on free wheel retaining wedge -arrow- with pliers.
- Remove planet carrier with dished spring.
- Remove reverse gear brake -B1- plates.
Note:
- It is not necessary to remove input gear to disassemble transmission. Input gear, Service and Repair.
- Transmission, assembling.
Removing Clutch -K1- From -K3-,
Clutches -K1- and -K3- are pressed together.
Remove clutch -K1- from -K3- only if one of the clutches is to be disassembled or replaced.
- Ensure that tool press surface is flat and not damaged.
Pin of tube 3110 must face plate VW 402.
- Hold turbine shaft when pressing off.
Pressing Clutch -K1- Onto -K3-
- Insert new O-ring in recess in turbine shaft -arrow-.
- Lubricate O-ring with ATF
- Clip -2- axial needle bearing -1- with washer to 3rd and 4th gear clutch -K3-.
- Ensure 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).
- Press clutch -K1- on carefully until you feel it stop.
CAUTION!
- Do not exert excess pressure on clutches.
Transmission, Assembling
- Installing O-ring in planet carrier.
Note:
- If you replace planet carrier, adjust.
- Insert axial needle bearing with washers and planet carrier in input gear.
1. Input gear is installed in transmission housing.
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 O-ring installed
- Place washer and axial needle bearing on small sun gear in planet carrier.
- Center 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 must comply with transmission code letters.
- Insert dished washer with convex facing toward free wheel.
Note:
When replacing
- Transmission housing
- Free wheel
- Piston for reverse gear brake -B1-
- or plates
then adjust -B1-.
- Preload free wheel rollers with assembly ring 3267 and insert free wheel.
- Install circlip for free wheel -b- and circlip for support tube -a-.
- Insert circlip gaps over free wheel retaining wedge -arrow-.
- Install Transmission Vehicle Speed Sensor (VSS) -G38-.
- Check -B1- measurement. Refer to Adjustments.
- Insert components in transmission housing, starting with large sun wheel down to small input shaft.
1. Large sun wheel
2. Needle bearing washer (collar faces large sun wheel)
3. Axial needle bearing
4. Large input shaft
5. Axial needle bearing
6. Needle bearing
7. Small input shaft
- Install small axle shaft bolt -1- with washer -2- and shim -3- Tightening torque 30 Nm (22 ft. lbs.).
- Insert shim -3- onto small input shaft shoulder -arrow-.
- Determining shim thickness, adjusting planet carrier.
- Check planet carrier measurement. Refer to Adjustments.
- Snap in axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.
1. Axial needle bearing with thrust washer
2. 3rd and 4th gear clutch -K3-
- Ensure piston rings seat correctly on -K3-.
- Ensure ends of piston rings are hooked together.
- Insert 1st to 3rd gear clutches -K1- with 3rd and 4th gear clutch -K3-.
- Insert shims -arrow- in -K1-.
Note:
- Remeasure shim when replacing -K1-, -K2- or ATF pump clutch play between -K1- and -K2-, adjusting.
- 1 or 2 shims can be installed.
- Insert reverse gear clutch -K2-.
- Insert support tube for -B2- plate set -arrow- so that support tube groove engages in free wheel 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 last outer plate
- Insert three spring caps onto compression springs.
- Insert last outer plate -3 mm thick-
Determine shim. Refer to Adjustments.
- Install shim -a-.
- Insert retaining ring -b- onto shim. Smooth side must face shim.
Note:
When replacing
- Transmission housing
- Support tube
- ATF pump
- Retaining ring
- or plates
Adjust 2nd and 4th gear brakes -B2-. Refer to Adjustments.
Replacement parts for components must comply with transmission code letters.
- Install ATF pump seal.
- Install O-ring on ATF pump..
- Install ATF pump.
- Tighten bolts evenly, crosswise.
Note:
- Ensure O-ring is not damaged.
Tightening torque: 8 Nm (71 inch lbs.) then turn additional 90°.
Additional turns can be done in stages.
- Carry out check measurement of clutch play.
- Insert sealing plugs with O-rings -arrow-.
Installation position: Lug engages in oil channel.
- Install valve body with conductor strip.
- Install sump.
- Install cover -arrow- with gasket and spacer bushings.
Tightening torque: 8 Nm (71 ft. lbs.).
- Install ATF overflow line -1- and sealing plug -2- with new seal and tighten hand tight.
- Install torque converter.
- Transmission, install.
- Fill with 3 liters (3.16 qt.) of ATF. Check ATF level and top-up.