Transmission Disassembly

Required 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

Prerequisite
^ Transmission attached to transmission support 3336
^ Place drain pan under transmission.





^ Remove sealing plug -1- and ATF overflow pipe -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 3336.





^ Remove transmission housing cover with gasket -arrow-.
^ Remove oil pan. - Remove ATF screen.





^ Remove valve body with conductor strip.





^ Pull out sealing plugs for B1 -arrow-.





^ Remove ATF pump bolts -arrows-.





^ Install bolts -A- (M8) into threaded holes for ATF pump.
^ Press ATF pump from transmission by turning bolts -A- evenly.





^ Remove all clutches together with support sleeve, -B2- plates, springs and spring caps .
The clutches -K1- and -K3- are pressed together.
Press clutch -K1- only off -K3- if one of the clutches must 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.
^ Pull out small input shaft.





^ Remove large input shaft -arrow-.





^ Remove large sun gear -arrow-.
^ Remove Transmission Vehicle Speed Sensor -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.





^ Pull out planet carrier with dished spring.
^ Remove reverse gear brake -B1- plates.

Note:
^ It is not necessary to remove input gear to disassemble planetary transmission. Input gear removing and installing.
^ Transmission, assembling.

Clutch -K1- from -K3, removing
Clutches -K1- and -K3- are pressed together.
Remove clutch -K1- from -K3- only if you replace or repair one of the clutches.
^ Be sure 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 the recess in the turbine shaft -arrow-.
^ Lubricate O-ring with ATF





^ Moisten axial needle bearing -1- and washer with ATF so that bearing, when installed , sticks to -2- 3rd and 4th gear clutch -K3-.
^ Be sure that the tool press surface is flat and not damaged.





^ Prepare -K1- and -K3- for pressing as illustrated.





^ Before pressing on, align VW418 A centrally onto surface for axial needle bearing (this illustration shows -K3-).
^ Press clutch -K1- on carefully until you feel the stop.

CAUTION!
Do not apply further pressure on clutches.