Repair Instructions

Repair instructions, 01M, 4 Spd. A/T
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when performing vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points, are summarized here.

Transmission
^ When an automatic transmission is exchanged, the VW ATF in the planetary gearbox, and the gear oil in the final drive, is to be checked and topped up as necessary.





^ For transmission repairs, an exchange component is available for the shift elements, which is often more cost effective.
^ When installing the transmission, ensure that the dowel sleeves are fitted correctly.

Gaskets, oil seals





^ Radial shaft seals: Pack space between sealing lips with grease before installing.
^ Always install new O-rings.
^ After installing, check ATF level in planetary gearbox or gear oil in final drive, adjust to correct level if necessary.

Locking elements
^ Do not overstretch circlips; replace if necessary.
^ Circlips must be properly seated in the grooves.





^ Replace spring pins. Installed position: Slot longitudinal to line of force.

Shims
^ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
^ Check for signs of burr and damage. Install only shims which are in perfect condition.

Bearings
^ Tapered roller bearings are determined in the parts catalog according to transmission build date and code letters.
^ Always replace tapered roller bearings which are mounted on a shaft together and always use bearings from a single manufacturer.
^ Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.
^ Heat the inner races of tapered roller bearings to approximately 100°C before inserting.
^ Do not interchange the inner and outer races of same size bearings.





Nuts, bolts
^ Nuts and bolts for attaching covers and housings must be loosened and tightened in a crosswise pattern.
^ Do not distort particularly sensitive parts, e.g. valve body, and loosen or tighten diagonally in stages.
^ The tightening torques stated apply to un-oiled nuts and bolts.
^ Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Then insert the bolts with AMV 185 100 A1.
^ Always replace self-locking nuts.

Inner plates





^ Place new inner plates in ATF fluid for 15 minutes before installing.

Valve body
^ Replace the valve body if any of the selector elements are scorched.

Clutches
^ Clutches K1, K2 and K3 should be disassembled only for cleaning. If parts are faulty, replace clutch. Determine clutches according to transmission code letters.





Self-diagnosis (On Board Diagnostic or OBD)
^ Before repair work is performed on the automatic transmission, the cause of the malfunction should be determined as precisely as possible.