Planetary Gearbox, Disassembling and Assembling
Planetary gearbox, disassembling and assembling, 01M, 4 Spd. A/T
Special tools and equipment:
^ VW 309 Holding plate
^ VW 313 Support clamp
^ VW 353 Transmission support
^ VW 402 Thrust plate
^ VW 412 Press tool
^ VW 415 A Tube
Special tools and equipment:
^ VW 418 A Tube
^ 3110 Tube
^ 3267 Assembly ring
^ 3336 Transmission lifting beam
^ V.A.G 1331 Torque wrench or equivalent
Disassembling planetary gearbox
^ Transmission is attached to transmission support device 3336
- Place container under transmission.
- Remove sealing plug -1- and ATF overflow pipe -2-.
- Drain ATF.
3 - Sealing plug
4 - Cap
- Seal ATF cooler connections.
- Take out 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.
- Pull out sealing plugs for -B1- (arrow).
- Remove ATF pump bolts (arrows).
- Screw bolts -A- (M8) into tapped holes of ATF pump.
- Press ATF pump off gearbox by turning bolts -A- evenly.
- Remove strainer if installed.
The strainer is installed in the ATF cooler pipe.
- Take out all clutches with supporting tube, -B2- plates, springs and spring caps together.
The clutches -K1- and -K3- are pressed together.
Clutch -K1- must only be pressed off -K3- if one of the clutches is to 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 gearbox/input gear.
- Pull out small input shaft.
- Pull out large input shaft (arrow).
- Pull out large sun gear (arrow).
- Remove Transmission vehicle speed sensor -G38-.
- Remove supporting tube circlip -a- and freewheel circlip -b-.
- Take freewheel out of transmission housing by pulling on freewheel 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 the input gear to disassemble the planetary gearbox. Removing and installing input gear.
^ Assembling planetary gearbox.
Pressing clutch -K1- off -K3-
The clutches -K1- and -K3- are pressed together.
Clutch -K1- must only be pressed off -K3- if one of the clutches is to be disassembled or replaced.
- Ensure tool press surface is flat and not damaged.
The pin of tube 3110 faces to plate VW 402.
- Hold turbine shaft when pressing off.
Pressing clutch -K1- onto -K3-
- Insert new O-ring in recess in turbine shaft (arrow).
- Moisten O-ring with ATF.
- Clip axial needle bearing -1- with washer to 3rd and 4th gear clutch -K3- -2-.
- 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 stop is perceptible.
Note: Do not exert further pressure onto clutches!
Assembling planetary gearbox
- Fit O-ring into planet carrier.
Note: After replacing planet carrier, adjust.
- Insert axial needle bearing with washers and planet carrier in input gear as follows:
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 seal installed
- Place washer and axial needle bearing on small sun gear in planet carrier.
- Centralize washer and axial needle bearing in small sun gear.
- Insert inner and outer -B1- plates.
- Insert pressure plate with flat side facing plates.
The thickness of the pressure plate varies according to the number of plates. The replacement part is determined according to the transmission code letters.
- Insert dished washer with convex facing freewheel.
Note: When replacing
^ Transmission housing
^ Freewheel
^ Piston for reverse gear brake -B1-
^ or plates
then adjust -B1-.
- Preload freewheel rollers with assembly ring 3267 and insert free wheel.
- Install circlip for freewheel -b- and circlip for supporting tube -a-.
- Insert circlip gaps over freewheel retaining wedge (arrow).
- Install Transmission vehicle speed sender -G38-.
- Perform measurement check of -B1-.
- Insert components into 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 drive shaft bolt -1- with washer -2- and shim -3-, Tightening torque 30 Nm.
- Insert shim -3- onto small input shaft shoulder (arrow).
Note: Determining shim thickness go to adjusting planet carrier.
- Perform planet carrier check measurement.
- Clip 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 that 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 go to adjusting clutch play between -K1 -and -K2-.
^ 1 or 2 shims can be installed.
- Insert reverse gear clutch -K2-.
- Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel 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.
- Install shim -a-.
- Insert retaining ring -b- onto shim. Smooth side facing shim.
Note: When replacing
^ Transmission housing
^ Supporting tube
^ ATF pump
^ Retaining ring
^ or the plates
then the 2nd and 4th gear brakes -B2- are to be adjusted.
These components are determined as replacement parts according to the transmission code letters.
- Clean strainer.
- Install strainer.
Note: The strainer is located in the ATF cooler pipe.
- Install ATF pump seal.
- Fit O-ring on ATF pump.
- Install ATF pump.
- Tighten bolts evenly, in a crosswise pattern.
Note:
^ Ensure that the O-ring is not damaged.
^ Tightening torque: 8 Nm.
- Then turn bolts 90° further.
Turning further can be done in several stages.
- Perform check measurement of clutch play.
- Insert sealing plugs with O-rings (arrow).
Installed position: Tab engages in oil channel.
- Install valve body with conductor strip.
- Install oil pan.
- Install cover (arrow) with gasket and spacer bushes.
Tightening torque: 8 Nm.
- Screw in ATF overflow pipe -1- and sealing plug -2- with new seal hand tight.
- Install torque converter.
- Install transmission.
- Fill with 3 liters of ATF and check ATF level and top-up.