2nd and 4th Gear Brake
Required special tools and equipment:
^ VW 309 Fixture
^ VW 313 Support clamp
^ VW 353 Transmission support
^ 3459 Adjustment tool
^ Depth gauge
^ Straight edge
- To adjust, install.components without shim (item 11), without last outer plate (item 10) and without spring caps (item 6).
1 Transmission housing
2 Circlip
^ For supporting tube
3 Supporting tube -B2-
^ Spare part must match transmission code letters
^ Insert with notch engaging with free wheel wedge
4 Outer plate -B2-
^ 3 mm thick
5 Spring cap
^ Install first outer plate (item 4), then install spring cap
6 Spring cap
^ Do not install when adjusting -B2-
^ Install before installing last outer plate
7 Spring
^ Spare part must comply with transmission code letters
8 Inner plate -B2-
^ Quantity - Refer to Specifications
^ Spare part must comply with transmission code letters
9 Outer plate -B2-
^ Always install 2 mm thick outer plates
^ Quantity - Refer to Specifications
10 Outer plate -B2-
^ 3 mm thick
^ Do not install when adjusting -B2-
11 Shim
^ Do not install when adjusting -B2-
12 Retaining ring
^ When adjusting -B2-, insert with smooth side facing last inner plate (item 8)
Shim thickness, determining
The thickness of the shim(s) is determined by gap. Use the following formula:
Gap x = a - b - 2.65 mm
The measuring points are shown in the illustration to help you understand the formula. Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.
Dimension a, determining - see below.
Dimension b, determining - see below.
2.65 mm - The amount for settling is taken into account by force F
1 ATF pump
2 Retaining ring
3 Plates for -B2- without last outer plate
4 Support tube
Notes:
^ The first outer plate -arrow- is always 3 mm thick.
^ Do not install the last outer plate when you measure.
Calculating dimension "a":
Assemble planetary transmission except the last -B2- inner plate.
^ Place retaining ring with smooth side on last inner plate.
^ Place 3459 on retaining ring and turn that the 3 clips align with the 3 holes for the ATF pump.
^ Bolt 3459 to flange for ATF pump with 5 Nm (44 inch lbs.).
The plate stack for -B2- is now pressed together for the measurement.
^ Measure from pump flange/transmission housing -arrow- to 3459 with depth gauge.
Dimension a = Height of 3459 in mm, minus (-) the measured value
Example:
^ Note calculated value a.
^ Remove 3459.
^ Remove retaining ring.
Dimension "b, calculating
^ Push piston into ATF pump to stop.
^ Place new paper gasket onto ATF pump.
^ Place straight edge "B" onto stator support -arrow- and measure with depth gauge "A" to gasket of pump flange.
Example:
^ Note calculated value b.
Gap x = a - b - 2.65 mm
Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm
^ Determine size of shim(s) according to table:
Table of shims:
^ Select shim(s) according to the table and determine Part No. from parts catalogue.
In this example two shims must be installed (each 1.00 mm thick).
^ Insert three spring caps on compression springs.
^ Insert last outer plate -3 mm thick-.
^ Install correct shim(s) -a-.
^ Place retaining ring -b- onto shim(s). Smooth side must face shim.
^ Continue installation as described.