2ND and 4TH Gear Brake -B2-, Adjusting

2nd and 4th gear brake -B2-, adjusting, 01M, 4 Spd. A/T

Special tools and equipment required:

^ VW 309 Holding plate
^ VW 313 Support clamp
^ VW 353 Transmission support
^ 3459 Adjustment tool
^ Depth gauge
^ Straightedge

Note: 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 is determined according to transmission code letters
^ Insert so that notch locates on freewheel wedge

4 - Outer plate -B2-
^ 3 mm thick

5 - Spring cap
^ Install after installing first outer plate (item -4-)





6 - Spring cap
^ Do not install when adjusting -B2-
^ Install before installing last outer plate

7 - Spring
^ Spare part is determined according to transmission code letters

8 - Inner plate -B2-
^ Spare part is determined according to transmission code letters

9 - Outer plate -B2-
^ Always install 2 mm thick outer plates

10 - Outer plate -B2-
^ 3 mm thick
^ Do not install when adjusting -B2-





11 - Shim
^ Do not install when adjusting -B2-

12 - Retaining ring
^ Inserted with smooth side facing last inner plate (item -8-) when adjusting -B2-.

Determining shim(s)
The thickness of the shim(s) is determined by gap x. Use the following formula:





Gap x = a - b - 2.65 mm

The measuring points are shown in the illustration to help understanding the formula. Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.

Determining dimension -a-.
Determining dimension -b-.
2.65 mm = 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 - Supporting tube

Note: First outer plate (arrow) and last outer plate (do not install to measure!) are always 3 mm thick.

Calculating dimension "a"
- Assemble planetary gearbox up to last -B2- inner plate. Last outer plate and shim are not installed.





- Place retaining ring with smooth side onto last inner plate.
- Place 3459 onto retaining ring and turn so that 3 clips align with 3 holes for ATF pump.
- Bolt 3459 to flange for ATF pump with 5 Nm.
The plate packet for -B2- is now pressed together for the measurements.





- Measure from pump flange/transmission housing (arrow) to 3459 with depth gauge.
Dimension a = Height of 3459 in mm - measured value

Example:





- Note calculated value a.
- Remove 3459.
- Remove retaining ring.

Calculating dimension "b"
- Push piston into ATF pump onto stop.
- Place new paper gasket onto ATF pump.





- Place straightedge "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





- Determine thickness of shim(s) according to table and determine Part No. from parts catalog.

Note: In this example two shims must be installed (each 1.00 mm thick).

- Insert three spring caps onto compression springs.
- Insert last outer plate, 3 mm thick.





- Install correct shim(s) -a-.
- Place retaining ring -b- onto shim(s). Smooth side facing shim.