01m Users Manual[1]

AUTO TRANS DIAGNOSIS - 01M Article Text 1996 Volkswagen Golf For Volkswagen Technical Site Copyright © 1998 Mitchell Repair Information Company, LLC Thursday, August 19, 1999 11:28PM

ARTICLE BEGINNING

AUTO AUTOM MATI C TRANSM TRANSMI SSI ONS Vol ks wagen Type 01M Cabr i o, Gol f , Gol f I I I , GTI J et t a, J et t a I I I , Pas sa s at APPLICATION & LABOR TIMES

APPLI APPL I CA CATI TI ON & LABOR LABOR TI MES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Vehi ehi cl e Labor Labor Ti mes Tr ans. ans. Appl i cat i on ( 1) R & I ( 2) Over ver haul aul Model odel 1995 1995-- 96 Cabr i o . . . . . . . . . . . . . . . Go Gol f , GTI & J et t a 44- Cyl i nder Gas . . . . . . . . . . . . . . . . . Tur bo bo Di es el . . . . . . . . V6 . . . . . . . . . . . . . . . . . . . Passat 44- Cyl i nder Gas . . . . . . . . . . . . . . . . . Tur bo bo Di es el . . . . . . . . V6 . . . . . . . . . . . . . . . . . . .

4. 4 . . . . . . . . . 6. 3 . . . .

01M ( CL CL K)

4. 4 . . . . . . . . . 6. 3 4. 4 . . . . . . . . . 6. 3 4. 4 . . . . . . . . . 6. 3

.. . . .... . .. .

01M ( CL CL K) 01M ( C CK KZ) 01M ( CL CL B)

4. 9 . . . . . . . . . 6. 3 4. 9 . . . . . . . . . 6. 3 4. 9 . . . . . . . . . 6. 3

.. . . .... . .. .

01M ( CL CL K) 01M ( C CK KZ) 01M ( CL CL B)

( 1) - Removal and i nst al l at i on of t r ansmi ssi on f r om vehi cl e cha chassi s. ( 2) - On bench over ver haul f or t r ansmi ssi on and di f f er ent i al . DOES NOT i ncl ude r emoval oval and and i nst al l at i on. on. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

IDENTIFICATION

Vol kswag kswagen en Audi Gr oup oup ( VAG) t r ansax ansaxll e t ype ype i s cast i nt o t op of t r ansaxl saxl e ca case, next t o AT ATF coo cool er. Tr ansaxl saxl e cod code and and bui l d dat e ar e l ocat cat ed on t op of t r ansaxl saxl e ca case, se, next t o star t er . DESCRIPTION & OPERATION

Tr ansaxl saxl e i ncl udes a 4- spe speed aut omat i c t r ansmi ssi on, l ockock- up t or que con conver ver t er , f i nal dr i ve and sol enoi d- operat ed val val ve body. ody. See Fi g. 1. Under nor mal con condi t i ons, al l shi shi f t s ar ar e con cont r ol l ed by a Tr ansaxl e Cont r ol Modul e ( TCM TCM) . See Fi g. 2. Four t h gear i s an over ver dr i ve gear.

AUTO TRANS DIAGNOSIS - 01M Article Text (p. 2) 1996 Volkswagen Golf For Volkswagen Technical Site Copyright © 1998 Mitchell Repair Information Company, LLC Thursday, August 19, 1999 11:28PM

Fi g. 1: Cr oss- Sect i onal onal Vi ew Of Transaxl Transaxl e Componen onentt s Cour our t esy of Vol kswag kswagen en Uni t ed St at es, I nc.


Fi g. 2: I dent i f yi ng TCM & Shi f t Lock Lock El ect r i cal cal Component s Cour our t esy of Vol kswag kswagen en Uni t ed St at es, I nc. The t r ansmi ssi on el ement s con consi st of a pl anet ary gear ear set , one- way r ol l er cl ut ch, ch, 3 appl y cl ut che ches, 2 br ake ake cl ut che ches an and a t or que con conver ver t er l ock- up cl ut ch. ch. See Fi gs. 1 and 3. Al l 4 f or war d gear s ar e hydr ydr aul i cal cal l y act i vat vat ed. When t he l ockock- up cl ut ch i s eng engaged aged,, t he f orwar orwar d gea gearr s becom become mechan echanii cal l y dr i ven ven by el el i mi nat i ng t or que co conver t er sl i p. The l ockck- up cl ut ch i s


engaged dependi ng on engi ne l oad and vehi cl e speed. Power f r om t he t r ansmi ssi on i s connect ed t o t he dr i ve pi ni on t hr ough t r ansf er gear s. A r i ng gear and di f f er ent i al assembl y ar e connect ed t o f l anges whi ch spi n t he dr i ve axl es. The el ect r oni c cont r ol consi st s of a TCM ( l ocat ed under r ear seat ) , cont r ol sol enoi ds, var i ous sensor s and swi t ches. The cont r ol sol enoi ds di r ect oi l pr essur e i nsi de t he val ve body. Sol enoi d val ves No. 1- 4 cont r ol t he appl y and br ake cl ut ches. Sol enoi d val ves No. 5 and 7 cont r ol shi f t smoot hness. Sol enoi d val ve No. 6 i s a f r equency val ve and cont r ol s t he mai n hydr aul i c pr essur e. The TCM cont r ol s t he mai n hydr aul i c pr essur e by varyi ng t he dut y cycl e. The TCM moni t or s i nput and out put si gnal s. I f el ect r i cal pr obl ems occur , TCM wi l l r ecor d f aul t s i n TCM memor y and may go i nt o f ai l - saf e mode ( al so known as emergency r unni ng mode) . I f TCM ent ers f ai l - saf e mode, t he t r ansaxl e wi l l oper at e manual l y i n r ever se, 1st or 3r d gear . I n f ai l - saf e mode, 3r d gear oper at es wi t h gear sel ect or i n 2nd, 3r d or "D". I f engi ne i s st ar t ed wi t h TCM i n f ai l - saf e mode, TCM act i vat es 3r d gear hydr aul i cal l y. The TCM memor y can onl y be read usi ng Scan Tool ( VAG 1551) and Adapt er ( VAG 1551/ 3) . The TCM al so cont r ol s shi f t l ock syst em. Thi s syst em l ocks t he gear sel ect or i n Par k or Neut r al posi t i on unl ess t he br ake pedal i s pr essed. The TCM uses a shi f t l ock cont r ol r el ay t o r el ease a gear sel ect or mount ed sol enoi d. See Fi g. 2.

Fi g. 3: Vi ew Of Tr ansaxl e Cl ut ch El ement s Cour t esy of Vol kswagen Uni t ed St at es, I nc.


LUBRICATION & ADJUSTMENTS

NOTE:

See appr opr i at e AUTOMATI C TRANSMI SSI ON SERVI CI NG ar t i cl e i n TRANSMI SSI ON SERVI CI NG sect i on. TROUBLE SHOOTING

SYMPTOM DIAGNOSIS

Leak At Tor que Conver t er Check dr i ve pl at e cl ear ance, t or que conver t er bushi ng, oi l seal or oi l pump assembl y. Repai r as necessar y. Tr ansaxl e Fl ui d I n Cool ant Faul t y t r ansaxl e oi l cool er . Repl ace t r ansaxl e oi l cool er and f r i cti on pl at es i n t r ansaxl e. Cl ean t r ansaxl e. Tr ansaxl e & Di f f er ent i al Oi l s Mi xed Repl ace " O" r i ng and dr i ve pi ni on seal on i nner beari ng suppor t . Gear Sel ect or Har d To Move Check gear sel ect or bet ween shi f t er and t r ansaxl e. Repai r as necessary. Check par ki ng l ock assembl y i nsi de t r ansaxl e. Repai r as necessar y. No Dr i ve I n 1st Gear Check f or f aul t y 1st - 3r d appl y cl ut ch or r ever se br ake cl ut ch. No Dr i ve I n "D", " 2" Or "3" Check f or f aul t y 1st - 3r d appl y cl ut ch or one- way cl ut ch. No 2nd Gear I n " D" , " 2" Or " 3" Check f or f aul t y 2nd- 4t h br ake cl ut ch. No 3r d Gear I n " D" Or " 3" Check f or f aul t y r ever se appl y cl ut ch. No 4t h Gear I n " D" Check f or f aul t y 2nd- 4t h br ake cl ut ch. No Rever se Check f or f aul t y r ever se appl y cl ut ch or r ever se br ake cl ut ch. No Dr i ve I n Al l For war d Gear Posi t i ons Check f or f aul t y 1st - 3r d appl y cl ut ch, r ever se br ake cl ut ch or one- way cl ut ch. Mi ss i ng Shi f t s Up Or Down


Check val ve body f or st i cki ng val ve( s) or f aul t y shi f t sol enoi d( s). Er r at i c Or Har sh Shi f t s Shor t i n wi r i ng t o s hi f t s ol enoi d( s ) or f aul t y s hi f t sol enoi d( s) . Check f or pr oper t hr ot t l e angl e adj ust ment . See TECHNI CAL SERVI CE BULLETI NS. Hars h Shi f t I n One Gear Onl y Det er mi ne el ement s i nvol ved. Ai r check el ement s. Check f or f aul t y s hi f t s ol enoi d or s hi f t val ve. St uck I n Emer gency Runni ng Mode Check f or i ncor r ect TCM i nst al l ed, f aul t y wi r i ng, bad sol enoi d el ectr i cal str i p ( i nsi de oi l pan) or stuck val ve. Par k Lock Wi l l Not Engage Check f or mi sadj ust ed sel ect or l ever cabl e. Check f or f aul t y l ocki ng mechani sm. Bucki ng Or Poor I dl i ng Check t hr ot t l e housi ng and ai r duct s f or l eaks. Check f or possi bl e ai r ent er i ng oi l pump pi ckup. Excess Engi ne RPM Dr op When Shi f t i ng I nt o 1st Gear Faul t y Powert r ai n Cont r ol Modul e ( PCM) . Engi ne St ar t s I n Gear Or No St ar t I n Par k/ Neut r al Check f or f aul t y Par k/ Neut r al saf et y swi t ch. Shi f t Lock Not Hol di ng Sel ect or I n Par k/ Neut r al Check f or f aul t y shi f t l ock sol enoi d, shi f t l ock mechani sm or bad TCM. MECHANICAL, HYDRAULIC & ELECTRICAL COMPONENTS

1) I f gear sel ector i s st uck i n Par k or Neut r al posi t i on, go t o SHI FT LOCK SYSTEM under TROUBLE SHOOTI NG. I f gear posi t i ons ar e mi ssi ng, shi f t qual i t y i s poor or no shi f t s ar e possi bl e, ensur e al l el ect r i cal connect i ons ar e okay and f l ui d l evel i s cor r ect. 2) I f pr obl ems ar e sti l l pr esent , di sconnect el ectr i cal connector at t r ansaxl e. Test dr i ve vehi cl e. Check i f t r ansaxl e wi l l oper at e manual l y i n r evers e and 1st gear . Move gear sel ect or t o 2nd, 3r d or "D" posi t i on. Tr ansaxl e shoul d operat e i n 3r d gear ( 2nd, 3r d or "D") . 3) I f t r ansaxl e oper at es as descr i bed, pr obl em may be el ect r i cal . See ELECTRONI C SELF- DI AGNOSTI CS. I f t r ansaxl e does not oper at e as descr i bed, probl em may be mechani cal or hydr aul i c. See ROAD TEST. NOTE:

I f t r ansaxl e does not operat e i n manual 1st gear , check 1st - 3r d appl y cl ut ch and r evers e br ake cl ut ch f or damage or


wear ear . I f t r ansaxl ansaxl e does oes not oper oper at e i n manu anual r ever ever se gear, gear, che check r ever ver se appl y cl ut ch and r ever ver se br ake cl ut ch f or damage or wear . ROAD TEST

WARNI NG: DO NOT excee exceed d saf e or l egal egal speed speed l i mi t s dur dur i ng r oad oad t est . 1) Road t est veh vehi cl e wi t h t r ansaxl saxl e i n "D" "D" r ange. Wi t h vehi vehi cl e at a spee speed d above above ki ckdow ckdown speed, speed, pr ess t hr ot t l e ped pedal al dow down and and not not e ki ckdow ckdown shi f t speeds. speeds. Compar par e ki ckdow ckdown shi f t speed speedss t o ki ckdow ckdown shi f t speed speed speci speci f i cat i ons. ons. See See KI KI CKDOWN SHI SHI FT SPE SPEED ED SPEC SPECII FI CATI ONS t abl e. NOTE:

I n t he f ol l owi ng t abl e, l et t er suf suf f i x f ol l owi ng gear appl i cat cat i on r ef er s t o Hydr ydr aul i c ( "H") "H") or Mecha chani cal cal ( "M") "M") gear ear oper oper at i on. on. Hydr ydr aul aul i c or manu anual gear gear operat operat i on depen epend ds on operat operat i ng mode ode of t or que conve converr t er l ockock- up cl ut ch.

KI CKDO KDOWN SHI SHI FT SPEED SPECI SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl ppl i cat i on Ki ckdow ckdown ( MPH) PH) 4- Cyl i nder ( CLK) LK) 1H- 1M 1M . . . . . . . . . . 1M- 2H 2H . . . . . . . . . . 2H- 2M 2M . . . . . . . . . . 2M- 3H 3H . . . . . . . . . . 3H- 3M 3M . . . . . . . . . . 3M- 4H 4H . . . . . . . . . . 4H- 4M 4M . . . . . . . . . . 4M- 4H 4H . . . . . . . . . . 4H- 3M 3M . . . . . . . . . . 3M- 3H 3H . . . . . . . . . . 3H- 2M 2M . . . . . . . . . . 2M- 2H 2H . . . . . . . . . . 2H- 1M 1M . . . . . . . . . . 1M- 1H 1H . . . . . . . . . . Tur bo Di esel es el ( CKZ) KZ) V6 ( CLB) 1H- 1M 1M . . . . . . . . . . 1M- 2H 2H . . . . . . . . . . 2H- 2M 2M . . . . . . . . . . 2M- 3H 3H . . . . . . . . . . 3H- 3M 3M . . . . . . . . . . 3M 3 M- 4H 4H . . . . . . . . . . 4H- 4M 4M . . . . . . . . . . 4M 4 M- 4H 4H . . . . . . . . . . 4H- 3M 3M . . . . . . . . . . 3M- 3H 3H . . . . . . . . . . 3H- 2M 2M . . . . . . . . . . 2M- 2H 2H . . . . . . . . . .

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30- 34 34 30- 34 34 61- 65 65 61- 65 65 85- 89 89 85- 89 89 85- 89 89 86- 83 83 86- 83 83 61- 57 57 61- 57 57 61- 57 57 26- 22 22 26- 22 22 ( 1)

37- 41 41 37- 41 41 76- 80 80 76- 80 80 111- 11 115 111- 11 115 111- 11 115 112- 10 108 112- 10 108 . . 75- 71 71 . . 75- 71 71 . . 75- 71 71


2H- 1M 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1M- 1H 1H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32- 28 28 32- 28 28

( 1) - I nf or mat i on not avai vai l abl e f r om manuf act ur er . ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 2) Connect scan t ool ool and appr opr i at e adapt er t o di agn agnost i c connect connect or . Sel ect f unct unct i on 08 " READ EAD MEASU EASUR RI NG VALUE LUE BLO BLOC CK". Test sol eno enoi d va val ves ves and and upshi f t spe speeds eds f ol l owi ng scan t ool manuf act ur er s i ns t r uc t i ons . 3) I f t r ansaxl saxl e does not shi shi f t wi t hi n spe speci f i ed MPH r ange, and scan scan t ool val val ues ar ar e wi t hi n spe speci f i cat cat i on, det er mi ne af f ect ed el ement s . See APPL APPLY Y & BR BRAK AKE E CLUTC CLUTCH H APPLI CA CATI TI ON. 4) I f al l appl y and br ake cl ut ch el ement s ar e af f ect ed, che check oi l pump, oi l f i l t er , coo cool er l i nes, sol sol enoi d val ve No. 6, and con condi t i on of of t or que co conver ver t er and/ or engi ne. Repai r as nece necessar ssar y. 5) I f one one or more app appl y and and br ake ake cl ut ch el ement ent s ar e af f ect ed, r emove val val ve body. Loca Locatt e appr opr i at e f l ui d ci r cui cui t i n t r ansax ansaxll e case case an and val val ve body. ody. Check f or l eaks eaks and/ and/ or bl ockag ockage. e. Repai epai r as necessar necessar y. 6) I f hydr ydr aul i c ci r cui cui t s ar e okay, kay, or pr obl ems wi t h appl y and br ake cl ut ch el ement ent s ar e mecha chani cal cal , r epai r t r ansaxl saxl e. NOTE: TE:

I f t r ansaxl ansaxl e does does not operat operat e i n manua anuall 1st gea gearr , check check 1st - 3r d app appl y cl ut ch and and r evers evers e br ake ake cl ut ch f or dam damage age or wear ear . I f t r ansaxl ansaxl e does oes not oper oper at e i n manu anual r ever ever se gear, gear, che check r ever ver se appl y cl ut ch and r ever ver se br ake cl ut ch f or damage or wear .

APPLY & BRAKE CLUTCH APPLICATION

APPLY APPL Y & BR BRAK AKE E CLUTCH CLUTCH APPLI APPL I CA CATI TI ON ( 1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Gear ear Appl i cat i on El ement ent s I n Use 1st Ge Gear . . . . . . . . . . 1st - 3r d Appl y & One- Way Cl ut ch Hol di ng 2nd Gear . . . . . . . . . . . . . . . . . . . 1s t - 3r d Appl y & 2nd- 4t h Br ak a ke 3r d Gear . . . . . . . . . . . . . . . . . . . . 1s t - 3r d & 4t h Appl y Cl ut c he hes 4t h Gear . . . . . . . . . . . . . . . . . . . . . . . 4t h Appl y & 2nd- 4t h Br ak ake Rever s e . . . . . . . . . . . . . . . . . . . . Rever s e Appl y & Rever s e Br a ke ke Par k & Neut r al . . . . . . . . . . . . . . . . Al l Appl y & Br ak a k e Cl ut c he hes Rel eased sed Or I nef f ect i ve ( 1) - Al l f or war d ge gear el ement s show shown ar e i n "hyd "hydr aul i c- st at e". For For ward gear ear el ement ent s swi swi t ch t o a " mechan echanii cal - st at e" wi t h t he addi t i on of t or que con conver ver t er l ockck- up cl ut ch ap appl y. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT LOCK SYSTEM

Oper at i on Op


Al l model s ar e equi pped wi t h an el ect r oni c shi shi f t l ock ock syst em. TCM TCM cont r ol s s hi f t l ock s yst ys t em. See Fi g. 2. Thi s s yst ys t em l ocks ock s gear sel sel ect or i n Par Par k or or Neut r al posi t i on unl ess br br ake pedal i s pr pr essed ssed. TCM TCM uses s hi f t l ock cont r ol r el ay t o r el ease a s ol enoi d mount ed on gear ear sel ect or assembl y. NOTE:

Shi f t l ock r el ay wi l l not not l ock gear sel sel ect or when veh vehi cl e speed i s gr eat eat er t han han 3 MPH. PH.

A mecha chani cal cal con cont r ol cab cabl e pr even vent s i gni t i on key key f r om bei ng r emoved ved unl ess ge gear sel sel ect or i s i n Par Par k po posi t i on. Wi t h i gni t i on key key r emoved ved, gear sel sel ect or l ocks i n Pa Par k po posi t i on. NOTE:

I f ba bat t er y i s di sconn sconnect ed or di scha schar ged, ge gear sel ect ect or can can be moved ved out of Par Par k posi t i on by t ur ni ng i gni t i on key key t o STAR TART posi t i on. on.

Fun Funct i onal onal Check 1) Wi t h i gni t i on key key r emoved oved,, ensur ensur e gear ear sel ect or canno cannott be moved f r om "P" po posi t i on. I nser ser t key key i n i gni t i on swi swi t ch. ch. 2) Tur Tur n i gni t i on on. on. Ensur nsur e gear ear sel ect or can onl onl y be moved oved wi t h br br ake peda edal pr essed. ssed. Move gear sel ect or t o "N" "N" posi t i on. 3) Wi t hout out pr essi ng br ake ake ped pedal , ensur ensur e gear gear sel ect or cann cannot move ove out out of " N" posi posi t i on. on. Pr ess br br ake ake pedal edal down. Ensur e i t i s now now possi bl e t o move ove gear gear sel ect or. 4) I f shi shi f t l ock syst syst em does not oper at e as descri bed, adj ust gear sel sel ector, sol sol enoi d and con cont r ol cab cabl e. I f shi shi f t l ock syst syst em does not oper ate af af t er adj ust ment s ar ar e made ade, che check shi shi f t l ock el el ect ect r i cal cal syst em wi t h Scan Scan Tool Tool ( VAG 1551 1551)) . 5) See See t est i ng i nf or mat i on unde underr ELEC ELECTRO TRONI C SELFSELF- DI AGNOSTI STI CS. See Fi Fi gs. 10- 13. I f any pr pr obl obl ems ar e f ound, servi ce ha har ness or com component s. I f no pr pr obl ems ar e f ound, TCM may be be de def ect i ve. ve. I f shi f t l ock syst syst em st i l l does no not oper at e co cor r ect l y, che check f or wor n or or dam damaged aged par par t s and and r epl epl ace as as necess necess ar y. See See Fi gs. 2 and and 4.


Fi g. 4: Expl oded Vi ew Of Shi f t Lock & Gear Sel ect or Assembl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.


NOTE:

Per f or m t he f ol l owi ng adj ust ment s i n or der gi ven.

Cont r ol Cabl e Adj ust ment Loosen l ock scr ew at gear sel ect or l ever on t r ansaxl e. Move gear sel ect or i n cent er consol e to Par k posi t i on. Ensur e f r ont wheel s ar e l ocked. Ti ght en cabl e housi ng t o gear sel ect or l ever l ock screw. Shi f t Lock Sol enoi d Adj ust ment Pl ace gear sel ector i n "N" or "P" posi t i on. Loosen shi f t l ock sol enoi d mount i ng scr ews. I nser t a . 019" ( . 30 mm) f eel er gauge bet ween shi f t l ock sol enoi d push r od and shi f t l ever . See Fi g. 5. I f necessary, move shi f t l ock sol enoi d and t i ght en scr ews.

Fi g. 5: Adj ust i ng Shi f t Lock Sol enoi d Cour t esy of Vol kswagen Uni t ed St at es, I nc. Shi f t Lock Cabl e Adj ust ment 1) Move gear sel ect or t o " 1" posi t i on. Remove st eer i ng col umn cover s. Tur n i gni t i on key t o START posi t i on and r el ease. Check cl ear ance bet ween shi f t l ock cabl e l ever and i gni t i on swi t ch l ocki ng pi n. 2) Cl ear ance shoul d be . 028" ( . 70 mm) . I f cl earance i s not cor r ect, l oosen l ock nut on shi f t l ock cabl e sheat h. Posi t i on shi f t l ock cabl e l ever t o obt ai n cor r ect cl ear ance. Ti ght en l ock nut . See Fi g. 6. Ti ght en gear sel ect or housi ng scr ews and i nst al l st eer i ng col umn cover s.

Fi g. 6: Adj ust i ng Shi f t Lock Cabl e Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Removal & I nst al l ati on ( Cont r ol Cabl e) Remove l ower cover f r om cent er consol e. Remove ci r cl i p f r om cont r ol cabl e end. Remove exhaust cover s. On model s equi pped wi t h V6 engi nes, r emove cat al yt i c conver t er . On al l model s, l oosen l ock nut and r emove cont r ol cabl e f r om shi f t l ever on t r ansaxl e. To i nst al l , r ever se r emoval pr ocedur e. Adj ust cont r ol cabl e. See CONTROL CABLE ADJ USTMENT under SHI FT LOCK SYSTEM. Removal & I nst al l at i on ( Shi f t Lock Cabl e) 1) Remove shi f t l ever handl e. Remove cent er consol e cover . Di sconnect negat i ve bat t ery cabl e and wai t 30 seconds. 2) Usi ng Tor x wr ench, r emove ai r bag r et ai ni ng scr ews f r om r ear si de of steer i ng wheel . Li f t of f ai r bag uni t f r om steer i ng wheel , and ti l t ai r bag uni t downwar d. Di sconnect wi r i ng connect or f r om ai r bag uni t . Remove st eer i ng wheel . Remove dash panel . 3) Pl ace gear sel ect or i n r ear posi t i on. Loosen scr ew hol di ng cabl e sheat h to gear sel ect or suppor t . Remove cabl e f r om l ever . See Fi g. 7. 4) Remove cover f r om i gni t i on swi t ch. Remove spri ng cl i p hol di ng cabl e housi ng t o i gni t i on assembl y. Li f t and t i l t shi f t l ock cabl e housi ng upwar d. Pul l up shi f t l ock cabl e unt i l shi f t l ock cabl e unhooks f r om i gni t i on swi t ch. See Fi g. 8.

Fi g. 7: Removi ng Shi f t Lock Cabl e Fr om Shi f t Lever Suppor t Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 8: Removi ng Shi f t Lock Cabl e From I gni t i on Swi t ch Cour t esy of Vol kswagen Uni t ed St at es, I nc.


5) Remove shi f t l ock cabl e f r om under dash near A/ C- heat er housi ng and r emove f r om vehi cl e. To i nst al l , posi t i on shi f t l ock cabl e t hr ough under - dash panel s. See Fi g. 9. To compl et e i nst al l at i on, r ever se removal pr ocedur e. Adj ust shi f t l ock cont r ol cabl e. See SHI FT LOCK CABLE ADJ USTMENT under SHI FT LOCK SYSTEM.

Fi g. 9: Rout i ng Shi f t Lock Cabl e To I gni t i on Swi t ch Cour t esy of Vol kswagen Uni t ed St at es, I nc. ELECTRONIC SELF-DIAGNOSTICS RETRIEVING TROUBLE CODES

1) El ect r oni c cont r ol consi st s of a TCM ( l ocat ed under r ear seat ) , cont r ol sol enoi ds, and var i ous sensor s and swi t ches. TCM moni t or s i nput and out put si gnal s. See Fi g. 2. 2) I f TCM det ects pr obl ems i n t r ansaxl e- r el at ed ci r cui t s or devi ces, TCM may r ecor d a t r oubl e code i n memor y. To r et r i eve obt ai n t r oubl e codes, use Scan Tool ( VAG 1551) and Adapt er ( VAG 1551/ 3) . Al l t r oubl e code and r el at ed t est i ng i nf or mat i on i s cont ai ned i n scan t ool .

TESTING

ELECTRICAL

NOTE:

Manuf act urer does not provi de el ect r i cal component t est s or speci f i cat i ons. Al l t est i ng i nf or mat i on i s cont ai ned i n Scan Tool ( VAG 1551) .

1) To i sol at e TCM ci r cui t pr obl ems wi t hout a scan t ool , ci r cui t r esi st ance and vol t age can be checked by usi ng Test Box ( VAG 1598/ 18) . 2) When checki ng ci r cui t vol t age, l eave bat t er y connect ed wi t h t est box connect ed t o TCM and TCM vehi cl e har ness. When checki ng ci r cui t r esi st ance, di sconnect negat i ve bat t er y cabl e and connect t est


box t o TCM vehi cl e harness. Leave TCM di sconnect ed. 3) Measur e vol t age and r esi st ance bet ween speci f i ed socket s on t est box. See Fi gs. 10- 13. I f a pr obl em i s f ound, ser vi ce har ness or c omponent s as necessary. I f no pr obl em i s f ound, TCM may be def ecti ve.

Fi g. 10: Test i ng TCM Har ness & Component s ( 1 Of 4) Cour t esy of Vol kswagen Uni t ed St at es, I nc.







HYDRAULIC PRESSURE

Check oper at i on of appl y and br ake cl ut ches by ai r checki ng f l ui d passages of val ve body and t r ansaxl e case. I nst al l Pr essur e Gauge ( VAG 1702) t o t r ansaxl e pr essur e t ap l ocat ed near di pst i ck t ube. Check mai n hydr aul i c pr essur e under nor mal dr i vi ng condi t i ons. See MAI N PRESSURE t abl e. I f mai n hydr aul i c pr essur es ar e not cor r ect , check f or i ncor r ect i dl e speed, pr obl em wi t h pump or st i cki ng val ves i n val ve body. Repai r as necessar y. MAI N PRESSURE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on psi ( Bar ) " D" I dl e 2000 " R" I dl e 2000

RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49- 55 ( 3. 4- 3. 8) RPM ( 1) . . . . . . . . . . . . . . . . . . . . . . . 146- 164 ( 10. 1- 11. 3) RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94- 109 ( 6. 5- 7. 5) RPM ( 1) . . . . . . . . . . . . . . . . . . . . . . . 334- 348 ( 23. 0- 24. 0)

( 1) - Wi t h sol enoi d val ve connect or di sconnect ed. Af t er t est , r econnect sol enoi d val ves and usi ng appr opr i at e scan t ool , er ase t r oubl e codes f r om memor y. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ STALL SPEED

CAUTI ON: DO NOT oper at e engi ne at st al l speed f or mor e t han 5 seconds. I f you need t o r epeat st al l speed t est , wai t 20 seconds. 1) Engage par ki ng br ake and bl ock dr i ve wheel s. Connect t achomet er t o engi ne. War m engi ne t o nor mal oper at i ng t emper at ur e. 2) Fi r ml y pr ess br ake pedal . Move gear sel ect or t o " D" posi t i on. Open t hr ot t l e t o wi de open t hr ot t l e posi t i on. Not e engi ne speed and rel ease t hr ot t l e pedal . 3) Compar e measur ed st al l speed wi t h st al l speed speci f i cat i on. See STALL SPEED SPECI FI CATI ONS t abl e. I f st al l speed i s wi t hi n r ange, t est i s compl et e. 4) I f st al l speed i s up t o 200 RPM t oo l ow, check engi ne condi t i on and adj ust ment s. I f st al l speed i s gr eat er t han 200 RPM t oo l ow, t or que conver t er i s f aul t y. I f stal l speed i s t oo hi gh, check 1st - 3r d appl y cl ut ch or one- way cl ut ch f or s l i ppi ng or damage. STALL SPEED SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on RPM CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600- 2900 CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2250- 2550 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ


ON-VEHICLE SERVICE DRIVE AXLE SHAFTS

See appr opr i at e AXLE SHAFTS ar t i cl e i n AXLE SHAFTS & TRANSFER CASES sect i on. OIL COOLER FLUSHING

1) Remove exter nal oi l f i l t er . Remove oi l l i nes and al l ow f l ui d t o dr ai n. Usi ng pr essur i zed sol vent , f l ush r emai ni ng f l ui d and debr i s f r om oi l l i nes and cool er . Repeat f l ushi ng i f necessar y. 2) Use pr essur i zed shop ai r t o r emove sol vent f r om oi l l i nes and oi l c ool er . I ns t al l a new ext er n al oi l f i l t er . TRANSAXLE COMPONENTS

Fol l owi ng component s may be ser vi ced wi t h t r ansaxl e i n vehi cl e. For r emoval and i nst al l at i on pr ocedur es, see TRANSAXLE DI SASSEMBLY. * * * * * *

Dr i ve Fl anges Ext er nal Oi l Fi l t er Gear Sel ect or Lever Mul t i f unct i on Swi t ch, Speedomet er Dr i ve Shaf t & Speed Sensor Oi l Pan & Val ve Body Ass embl y Pl anet ar y Gear Cover

REMOVAL & INSTALLATION

See appr opr i at e AUTOMATI C TRANSMI SSI ON REMOVAL ar t i cl e i n TRANSMI SSI ON SERVI CI NG sect i on. TORQUE CONVERTER

1) Remove t or que conver t er . Check t or que conver t er f or any wear or damage, and r epl ace i f necessar y. I f t or que conver t er i s bei ng r eused, dr ai n ol d f l ui d. 2) Ext r act ATF f r om t or que conver t er usi ng Tor que Conver t er Ser vi ce St at i on ( VAG 1358 A) and Pr obe ( VAG 1358 A/ 1) . TRANSAXLE DISASSEMBLY TRANSAXLE UNIT

1) Remove t or que conver t er . Remove oi l pan and val ve body assembl y. Remove seal i ng pl ug f r om t r ansaxl e case. See Fi g. 14. 2) Measur e and r ecor d t ur bi ne shaf t end pl ay. See Fi g. 15. Remove oi l pump bol t s. Usi ng t wo M8 bol t s, r emove oi l pump f r om f r ont of t r ansaxl e. See Fi g. 16.


3) Remove al l cl ut ches wi t h suppor t t ube, 2nd- 4t h gear cl ut ch pl at es, spri ngs and spr i ng caps t ogether . See Fi gs. 17 and 18. 4) Lock dr i ve shel l i n pl ace by i nser t i ng a scr ewdr i ver t hr ough hol e of l arge sun gear i nt o si de of t r ansaxl e case. See Fi g. 19. Loosen and r emove smal l pl anet ar y dr i ve shaf t bol t , washer and shi m. See Fi g. 20. Remove smal l pl anet ary dr i ve shaf t . 5) Remove l ar ge dr i ve shaf t and sun gear . Remove Vehi cl e Speed Sensor ( VSS) f r om t r ansaxl e case. Remove suppor t i ng t ube and one- way cl ut ch ci r cl i ps. Remove one- way cl ut ch assembl y. 6) Remove pl anet ar y car r i er wi t h di shed spr i ng. Remove r ever se br ake cl ut ch ass embl y. See Fi gs. 17, 20 and 21. DO NOT r emove i nput gear assembl y, unl ess bear i ng or gear damage i s pr esent .

Fi g. 14: Expl oded Vi ew Of Oi l Pan & Val ve Body Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 15: Checki ng Tur bi ne Shaf t End Pl ay Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 16: Removi ng Oi l Pump Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 17: Expl oded Vi ew Of Tr ansaxl e Component s Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 18: Removi ng Tur bi ne Shaf t Wi t h 2nd- 4t h Br ake Cl ut ch & 1st 3r d Appl y Cl ut ch Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 19: Locki ng Smal l Sun Gear Dr i ve Shel l Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 20: Removi ng Smal l Pl anet ar y Dr i ve Shaf t Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 21: Removi ng Pl anet ar y Car r i er & Rever se Br ake Cl ut ch Ass embl y Cour t esy of Vol kswagen Uni t ed St at es, I nc. FINAL DRIVE & TRANSFER GEARS

1) Dr ai n gear oi l . At t ach I NCH- l b. t orque wr ench t o a 1 5/ 8" ( 41 mm) socket wr ench. See Fi g. 22. Measur e and r ecor d t ot al r ol l er bear i ng t ur ni ng tor que of dr i ve pi ni on gear . Thi s measurement i s r equi r ed f or r eassembl y ref er ence i f r ol l er bear i ngs ar e r eused. 2) Engage par ki ng pawl . Usi ng a 7/ 8" ( 22 mm) Al l en wr ench socket , r emove f ast ener nut . See Fi g. 22. Remove di shed washer, shi m and bear i ng. 3) I nst al l f ast ener nut . Usi ng Pressi ng Adapt er ( VW771) , t hr ead t ool unt i l 1/ 8" cl earance i s present between beari ng r ace and f ast ener nut . 4) Pul l i nput gear out unt i l i t bot t oms i n pr essi ng adapt er .


Remove pr essi ng adapt er . Remove i nput t r ansf er gear assembl y f r om t r ansaxl e case. 5) Remove speedomet er dri ve shaf t . See Fi g. 23. On l ef t axl e f l ange, r emove bol t and r emove axl e f l ange. On r i ght axl e f l ange, r emove ci r cl i p. Usi ng pul l er , r emove r i ght axl e f l ange. 6) Remove di f f er ent i al r i ng gear cover . I f bear i ngs ar e bei ng r eused, mar k di f f er ent i al adj ust er r i ng (t or que conver t er si de) bear i ng car r i er t o t r ansaxl e case. Usi ng Bear i ng Adj ust er Ri ng Socket ( 3155) , r emove bot h di f f er ent i al beari ng car r i er s. See Fi g. 24. Remove di f f er ent i al assembl y f r om t r ansaxl e case. See Fi g. 23. 7) Remove dr i ve pi ni on and i nput t r ansf er gear cover ( i f not al r eady r emoved) . See Fi g. 25. Usi ng I NCH- l b. t orque wr ench, measur e t ur ni ng f or ce of dr i ve pi ni on and t r ansf er gear bear i ngs. Recor d measur ement f or r eass embl y. 8) Engage parki ng pawl . Remove nut f r om pi ni on. See Fi g. 26. Usi ng pul l er, r emove out put gear . See Fi g. 27. Remove sel ect or s haf t and par ki ng pawl assembl y. See Fi g. 36. Remove out er bear i ng suppor t . Remove par ki ng gear f r om pi ni on. Remove pi ni on and bear i ng f r om t r ansaxl e. Usi ng pi n socket , r emove i nner bear i ng support wi t h dr i ve pi ni on seal .

Fi g. 22: Removi ng I nput Tr ansf er Gear Fast ener Nut Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 23: Expl oded Vi ew Of Dr i ve Gear Assembl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 24: Removi ng Bear i ng Adj ust er Ri ng Bear i ng Carr i er Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 25: Locat i ng Pl anet ar y & I nput Gear Assembl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 26: Expl oded Vi ew Of Dr i ve Pi ni on & Out put Gear Ass embl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 27: Removi ng Pi ni on Dr i ve Gear Cour t esy of Vol kswagen Uni t ed St at es, I nc.


COMPONENT DISASSEMBLY & REASSEMBLY FINAL DRIVE

1) Di sassembl e di f f er ent i al . See Fi g. 28. I f r i ng gear or di f f er ent i al housi ng i s damaged, r epl ace di f f er ent i al housi ng. To r eassembl e di f f er ent i al , r ever se di sassembl y. NOTE:

I f di f f er ent i al bear i ngs ar e r epl aced, check di f f er ent i al si de bear i ng pr el oad and r i ng gear posi t i on. See FI NAL DRI VE & TRANSFER GEARS under TRANSAXLE REASSEMBLY.

2) Usi ng pul l er , r emove r ol l er bear i ng f r om di f f er ent i al housi ng. Remove speedomet er dr i ve gear and bushi ng. 3) Check al l bear i ng r aces i n adj ust er r i ngs and r epl ace i f necessar y. Usi ng hydr aul i c pr ess, r epl ace bear i ng race( s) . Repl ace each r ol l er bear i ng and race as a set .

Fi g. 28: Expl oded Vi ew Of Di f f er ent i al Cour t esy of Vol kswagen Uni t ed St at es, I nc.


OIL PUMP & 2ND-4TH BRAKE CLUTCH PISTON

Di sassembl e oi l pump and 2nd- 4t h br ake cl ut ch pi st on. Check f or worn or damaged par t s and repl ace as necessar y. Repl ace al l seal s and r eass embl e. See Fi g. 29. NOTE:

Speci f i cat i ons ar e not avai l abl e f r om manuf act ur er .

Fi g. 29: Expl oded Vi ew Of Oi l Pump & 2nd- 4t h Br ake Cl ut ch Pi st on Cour t esy of Vol kswagen Uni t ed St at es, I nc.


ONE-WAY CLUTCH

1) Di sass embl e one- way cl ut ch. Check f or wor n or damaged par t s and repl ace as necessar y. Compr ess each spr i ng and i nst al l i nt o cage. See Fi g. 30. 2) Hol d cage assembl y wi t h l ar ge l ugs up. I nst al l cage assembl y i nt o out er r i ng. See Fi gs. 31- 33. Rot at e cage cl ockwi se unt i l l ugs t ouch st op. I nstal l pi ston i nt o out er r i ng.

Fi g. 30: I nst al l i ng Spr i ngs I nt o Cage Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 31: I nst al l i ng Cage Assembl y I nt o Out er Ri ng Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 32: Checki ng One- Way Cl ut ch Rot at i on Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 33: I nst al l i ng Pi st on I nt o One- Way Cl ut ch Cour t esy of Vol kswagen Uni t ed St at es, I nc. PLANETARY CARRIER

NOTE:

Di sass embl y and r eass embl y pr ocedur es ar e not avai l abl e f r om manuf act ur er .

I nspect i on & Adj ust ment 1) I nspect pl anet ar y car r i er , pi ni on gear s, sun gear s and r el at ed par t s f or wear or damage. Repl ace part s as necessary. 2) Assembl e sun gear dr i ve shel l s, pl anet ar y car r i er , smal l sun gear , pi ni on dr i ve t r ansf er gear and al l r el at ed bear i ngs and washers ont o smal l pl anet ar y dr i ve shaf t . See Fi gs. 17 and 20. 3) Pl ace assembl y i nt o t r ansaxl e case. I nst al l adj ust ment shi m, washer and bol t t o pi ni on dr i ve t r ansf er gear end of smal l pl anet ar y dr i ve shaf t . Usi ng a scr ewdr i ver , l ock l ar ge sun gear dr i ve shel l t o t r ansaxl e case. See Fi g. 19. Ti ght en bol t t o 22 f t . l bs. ( 30 N. m) . 4) Pl ace Di al I ndi cat or Suppor t ( VW 382/ 7) on t op of assembl y. See Fi g. 34. Measur e end pl ay of smal l sun gear dr i ve shaf t . 5) I f end pl ay i s not . 009- . 014 ( . 23- . 37 mm) , r epl ace adj ust ment shi m. Adj ust ment shi ms r ange i n t hi ckness f r om . 040" ( 1. 00 mm) t o . 114" ( 2. 90 mm) i n . 004" ( . 10 mm) i ncr ement s.

Fi g. 34: Adj ust i ng Pl anet ar y Car r i er End Pl ay Cour t esy of Vol kswagen Uni t ed St at es, I nc.


APPLY CLUTCH PLATE APPLICATIONS

APPLY CLUTCH PLATE APPLI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Number Of Pl at es Rever se Cl ut ch I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1st - 3r d Cl ut ch I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Out er CLB & CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4t h Cl ut ch I nner CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Out er CLB & CKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ REVERSE APPLY CLUTCH

NOTE:

Soak al l f r i ct i on- f aced cl ut ch pl at es i n ATF f or at l east 15 mi nut es bef or e i nst al l at i on.

1) Mar k ci r cl i p f or i nst al l at i on r ef er ence and r emove. Di sassembl e cl ut ch pl at es. See Fi g. 35. Compr ess spri ng suppor t , and r emove ci r cl i p. Remove cl ut ch pi st on. 2) Check f or wor n or damaged par t s and r epl ace as necess ar y. Ensure check bal l i n cl ut ch housi ng i s not damaged. Pi st on seal i s par t of pi st on. I f damaged, r epl ace r ever se appl y cl ut ch pi st on. Reass embl e r ever se appl y cl ut ch. See APPLY CLUTCH PLATE APPLI CATI ONS t abl e. NOTE:

Assembl ed cl ut ch cl ear ance speci f i cat i on i s not avai l abl e f r om manuf acturer. Ensur e t hr ust pl at e i s i nst al l ed wi t h shoul der ed si de f aci ng ci r cl i p.


Fi g. 35: Expl oded Vi ew Of Rever se Appl y Cl ut ch Ass embl y Cour t esy of Vol kswagen Uni t ed St at es, I nc. REVERSE & 2ND-4TH BRAKE CLUTCHES

Rever se and 2nd- 4t h br ake cl ut ches ar e di sassembl ed and r eass embl ed dur i ng t r ansaxl e di sass embl y and r eass embl y. See TRANSAXLE DI SASSEMBLY and TRANSAXLE REASSEMBLY. TRANSAXLE CASE

1) Remove mul t i f unct i on swi t ch, al l seal s, manual val ve assembl y, par ki ng pawl and sensor s. I f necessar y, r emove par ki ng pawl pi n, det ent spri ng scr ews and sel ect or r od f or manual val ve f r om case. See Fi g. 36. I nspect bushi ngs and bear i ng r aces, and r epl ace i f necessar y. 2) I nst al l new "O" r i ng t o gear change shaf t . I nst al l gear


change shaf t . I nst al l par ki ng pawl pi n ( i f r emoved) . Usi ng a cent er punch, peen par ki ng pawl pi n. I nst al l operat i ng r od f or manual val ve, det ent spri ng screws, mul t i f unct i on swi t ch and new seal s.

Fi g. 36: Expl oded Vi ew Of Tr ansaxl e Case Component s Cour t esy of Vol kswagen Uni t ed St at es, I nc. TRANSFER GEARS

Usi ng pul l er and adapt er , r emove t aper ed bear i ng f r om out put gear . See Fi g. 37. Usi ng hydr aul i c pr ess, i nst al l bear i ng t o dr i ve pi ni on t r ansf er gear . Set t r ansf er and dr i ve pi ni on gear s asi de.


Fi g. 37: Removi ng Out put Gear Rol l er Bear i ng Cour t esy of Vol kswagen Uni t ed St at es, I nc. VALVE BODY

NOTE:

Di sass embl y and r eass embl y pr ocedur es ar e not avai l abl e f r om manuf act ur er .

1ST & 3RD APPLY CLUTCH

1) Remove suppor t r i ng. Mar k ci r cl i p f or i nst al l at i on r ef er ence, and remove ci r cl i p. Di sassembl e cl ut ch pl at es. See Fi g. 38. Remove di aphr agm spr i ng ci r cl i p. Compr ess spr i ng suppor t , and remove ci r cl i p. See Fi g. 39. Remove spr i ng pl at es and cl ut ch pi st on. 2) Remove pi st on r i ngs f r om pi st on. Pi st on seal i s par t of pi st on. I f damaged, r epl ace 1st - 3r d appl y cl ut ch pi st on. Remove seal r i ngs f r om t ur bi ne shaf t . Check f or wor n or damaged par t s and repl ace as necessar y. Ensur e check bal l i n cl ut ch housi ng i s not damaged.


Fi g. 38: Expl oded Vi ew Of 1st - 3r d Appl y Cl ut ch Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 39: Removi ng & I nst al l i ng Spr i ng Ci r cl i p Cour t esy of Vol kswagen Uni t ed St at es, I nc. 3) I nstal l new seal r i ngs t o cl ut ch pi ston, and i nst al l pi st on i n cl ut ch housi ng. I nst al l pl at e spr i ngs. Compr ess spr i ng suppor t and i nstal l ci r cl i p. See Fi g. 39. 4) I nst al l bot t om t hr ust pl at e wi t h smoot h si de f aci ng cl ut ch pl at e. I nst al l one i nner spl i ned and one out er spl i ned cl ut ch pl at e i nt o cl ut ch housi ng. See Fi g. 38. 5) Pl ace i nner pl at e car r i er on bench. I nst al l r emai ni ng cl ut ch pl at es t o i nner pl at e car r i er . See APPLY CLUTCH PLATE APPLI CATI ONS. I nser t t op t hr ust pl at e wi t h smoot h si de f aci ng cl ut ch pl at e. I nst al l suppor t r i ng wi t h st ep t abs up af t er i nst al l i ng t hr ust pl at e, f r i cti on pl at es and st eel pl at es. See Fi g. 40 . 6) I ns t al l i nner pl at e c ar r i er i nt o c l ut c h hous i ng. I ns t al l ci r cl i p i n cl ut ch housi ng. See Fi g. 41.

Fi g. 40: I nst al l i ng Suppor t Ri ng Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 41: I nst al l i ng Cl ut ch Housi ng Ci r cl i p Cour t esy of Vol kswagen Uni t ed St at es, I nc. 4TH APPLY CLUTCH

NOTE:

Soak al l f r i ct i on- f aced cl ut ch pl at es i n ATF f or at l east 15 mi nut es bef or e i nst al l at i on.

1) Mar k ci r cl i p f or i nst al l at i on r ef er ence and r emove. Di sassembl e cl ut ch pl at es. See Fi g. 42. Compr ess spr i ng suppor t r i ng, and r emove ci r cl i p. Remove spr i ng suppor t r i ng and spr i ng. Remove cl ut ch pi st on. 2) Remove f r ont i mpel l er seal r i ngs. DO NOT r emove i nner i mpel l er seal r i ngs unl ess damaged. Check f or wor n or damaged par t s and r epl ace as necess ar y. 3) Pi st on seal i s par t of pi st on. I f damaged, r epl ace 3r d- 4t h appl y cl ut ch pi st on. Reassembl e 3r d- 4t h appl y cl ut ch. See APPLY CLUTCH PLATE APPLI CATI ONS t abl e. NOTE:

Assembl ed cl ut ch cl ear ance speci f i cat i on i s not avai l abl e f r om manuf acturer. Ensur e t op t hr ust pl at e i s i nst al l ed wi t h shoul der ed si de f aci ng ci r cl i p.


Fi g. 42: Expl oded Vi ew Of 4t h Appl y Cl ut ch Cour t esy of Vol kswagen Uni t ed St at es, I nc.


TRANSAXLE REASSEMBLY FINAL DRIVE & TRANSFER GEARS

NOTE:

Reass embl y pr ocedur es i ncl ude bear i ng and shi m adj ust ment s. Per f or m al l st eps i n t he or der gi ven. I f no par t s wer e r epl aced, ski p adj ust ment st eps and r eassembl e f i nal dr i ve and t r ansf er gear assembl y usi ng new seal s. Ensur e t ur ni ng t or que of compl et e assembl y i s wi t hi n speci f i cat i ons. See I NPUT TRANSFER GEAR ADJ USTMENT & REASSEMBLY pr ocedur e. I f t ur ni ng t or que i s not wi t hi n speci f i cat i ons, check al l adj ust ment s.

Dr i ve Pi ni on Rol l er Beari ng Adj ust ment 1) I nst al l dr i ve pi ni on assembl y wi t h smal l er bear i ng and i nner bear i ng suppor t ( wi t h pi ni on seal and "O" r i ng) . I nst al l par ki ng gear ( r ounded si de f aci ng dr i ve pi ni on gear ) , par k l ock l ug and l ar ge pi ni on bear i ng race suppor t . Go t o next st ep. NOTE:

I nst al l dri ve pi ni on seal wi t h l i p openi ng f aci ng cl osest r ol l er bear i ng.

2) I f r eusi ng dr i ve pi ni on and l ar ge pi ni on bear i ng, DO NOT r emove exi st i ng shi ms f r om dr i ve pi ni on shaf t . See Fi g. 43. Go t o st ep 4) . I f r epl aci ng dr i ve pi ni on and/ or pi ni on bear i ngs, i nstal l l ar ge pi ni on r ol l er bear i ng t o dr i ve pi ni on. Go to next st ep. 3) Remove l ar ge r ol l er bear i ng r ace support . Pl ace t wo . 06" ( 1. 5 mm) t hi ck shi ms ont o dr i ve pi ni on shaf t . See Fi g. 43. I nst al l l ar ge r ol l er bear i ng r ace suppor t . Go t o next st ep. 4) I nst al l out put dr i ve pi ni on gear and nut . See Fi gs. 36 and 44. Engage parki ng l ug t o l ock dr i ve pi ni on shaf t . Ti ght en nut t o 184 f t . l bs. ( 250 N. m) . Go t o next st ep. 5) I f r eusi ng dr i ve pi ni on and l ar ge pi ni on bear i ng, go t o st ep 9) . I f r epl aci ng dr i ve pi ni on and/ or pi ni on bear i ngs, go to next st ep. 6) DO NOT r ot ate dr i ve pi ni on. Mount a di al i ndi cat or on t r ansaxl e case. See Fi g. 45. Move dr i ve pi ni on up and down ( DO NOT r ot at e) . Measur e and r ecor d end pl ay. Go t o next st ep.

Fi g. 43: I nst al l i ng Dr i ve Pi ni on Shi m Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 44: Locat i ng Fi nal Dr i ve Rol l er Beari ngs, Races & Adj ust ment Shi ms Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 45: Checki ng Dr i ve Pi ni on Rol l er Bear i ng End Pl ay Cour t esy of Vol kswagen Uni t ed St at es, I nc. 7) Dr i ve pi ni on r equi r es . 008" ( . 220 mm) pr el oad. To det er mi ne cor r ect shi m t hi ckness, per f or m t he f ol l owi ng pr ocedur e. Di mensi ons ar e gi ven as an EXAMPLE ONLY: *

Subt r act end pl ay r eadi ng . 037" ( 0. 93 mm) r ecor ded i n st ep 6) f r om . 118" ( 3. 00 mm) shi m pack added i n st ep 3) . Thi s wi l l


* * *

r esul t i n zer o end pl ay. Next , subt r act . 008" ( . 220 mm) t o achi eve r equi r ed pr el oad. Tot al shi m t hi ckness r equi r ed t o achi eve cor r ect pr el oad woul d be . 073" ( 1. 85 mm) . Shi ms ar e avai l abl e i n t hi ckness r angi ng f r om . 040- . 106" ( 1. 00- 2. 70 mm) , i n . 001" ( . 025 mm) i ncr ement s.

8) Remove nut , dr i ve pi ni on gear and bear i ng. I nst al l shi m cal cul at ed i n step 7) . Appl y gear oi l t o bear i ngs. I nst al l dr i ve pi ni on gear and nut . Ti ght en nut t o 184 f t . l bs. ( 250 N. m) t o seat bear i ngs. 9) Usi ng I NCH- l b. t orque wr ench, r ot at e t orque wr ench at l east 8 t ur ns t o det er mi ne t ur ni ng t or que. Measur e t ur ni ng t or que of dr i ve pi ni on rol l er beari ngs. See Fi g. 46. See DRI VE PI NI ON ROLLER BEARI NG SPECI FI CATI ONS t abl e. Af t er t ur ni ng t orque i s cor r ect , bend l ocki ng pl at e on nut . DRI VE PI NI ON ROLLER BEARI NG SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Tur ni ng Tor que New Bear i ngs . . . . . . . . . . . . . . . 7- 11 I NCH Lbs. (. 73- 1. 20 N. m) Used Bear i ngs . . . . . . . . . . . . . ( 1) Same As Bef or e Di sassembl y ( 1) - Recor ded dur i ng di sassembl y. See FI NAL DRI VE & TRANSFER GEARS under TRANSAXLE DI SASSEMBLY. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

Fi g. 46: Checki ng Pi ni on Rol l er Bear i ng Pr el oad Cour t esy of Vol kswagen Uni t ed St at es, I nc. I nput Tr ansf er Gear Adj ust ment & Reass embl y 1) Ensur e i nner r ace f or r ol l er bear i ng i s i nst al l ed i n t r ansaxl e case. 2) I nst al l i nput t r ansf er gear wi t h r ol l er bear i ng and axi al


needl e bear i ng ( f l at si de f aci ng i nput gear ) i nt o t r ansaxl e case. See Fi gs. 1, 44 and 47. Al i gn l ugs on out er r ol l er bear i ng t o f i t bet ween l ugs on i nner r ol l er bear i ng. See Fi g. 48. 3) I nst al l out er r ol l er bear i ng ( wi t hout di shed washer or shi m) on i nput t r ansf er gear . See Fi gs. 44 and 47. Engage par ki ng gear . Usi ng an Al l en- head socket , t i ght en f ast ener nut t o 74 f t . l bs. ( 100 N. m) . See Fi g. 49. 4) Remove f ast ener nut . Usi ng a di al i ndi cat or , measur e di st ance bet ween i nput t r ansf er gear and i nner r ace of r ol l er bear i ng. See Fi g. 50. Measur e t hi ckness of di shed washer .

Fi g. 47: Locat i ng I nput Tr ansf er Gear Assembl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 48: Al i gni ng Lugs On I nput Tr ansf er Gear Rol l er Bear i ngs Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 49: Ti ght eni ng Fast ener Nut On I nput Tr ansf er Gear Rol l er Bear i ngs Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 50: Checki ng Di st ance Bet ween I nput Transf er Gear & I nner Race Of Rol l er Bear i ngs Cour t esy of Vol kswagen Uni t ed St at es, I nc.


5) Add di shed washer t hi ckness t o di st ance measur ed i n st ep 3) . Subt r act . 007" ( . 180 mm) t o obt ai n shi m t hi ckness f or desi r ed r ol l er bear i ng pr el oad. Shi ms ar e avai l abl e i n t hi ckness r angi ng f r om . 040- . 106" ( 1. 00- 2. 70 mm) , i n . 001" ( . 025 mm) i ncr ement s. 6) I nst al l sel ected shi m. I nst al l di shed washer wi t h cur ved si de f aci ng f ast ener nut . Appl y ATF t o bear i ngs. I nst al l and ti ght en f ast ener nut t o 184 f t . l bs. ( 250 N. m) t o seat bear i ngs. 7) Usi ng I NCH- l b. t orque wr ench, r ot at e t orque wr ench at l east 8 t ur ns t o det ermi ne t ur ni ng t orque. Measur e combi ned t ur ni ng t or que of pi ni on and i nput t r ansf er gear r ol l er bear i ngs. See Fi g. 46. See I NPUT TRANSFER GEAR ROLLER BEARI NG SPECI FI CATI ONS t abl e. I NPUT TRANSFER GEAR ROLLER BEARI NG SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Tur ni ng Tor que New Bear i ngs Wi t hout Dr i ve Pi ni on Bear i ngs . . . 18 I NCH Lbs. ( 2. 0 N. m) Wi t h Dr i ve Pi ni on Beari ngs . . ( 1) 27 I NCH Lbs. ( 3. 0 N. m) Used Bear i ngs . . . . . . . . . . . . . ( 2) Same As Bef or e Di sassembl y ( 1) - Based on a dri ve pi ni on t or que of 9 I NCH Lbs. ( 1. 0 N. m) . ( 2) - Recor ded dur i ng di sassembl y. See FI NAL DRI VE & TRANSFER GEARS under TRANSAXLE DI SASSEMBLY. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 8) Remove f ast ener nut . I f necessar y, sel ect a shi m and r echeck r ol l er bear i ng pr el oad. I f r ol l er bear i ng pr el oad i s okay, appl y Locki ng Compound ( AMV 100 01) t o shaf t si de of r ol l er bear i ng. 9) Al i gn l ugs wi t h not ches of opposi t e r ol l er bear i ng. See Fi g. 48. I nst al l axi al needl e bear i ng wi t h f l at si de f aci ng dr i ve shaf t . Engage par ki ng gear l ug. I nst al l f ast ener nut and t i ght en t o 184 f t . l bs. ( 250 N. m) . Fi nal Dr i ve Assembl y 1) Oi l bear i ngs and pl ace di f f er ent i al assembl y i nsi de t r ansaxl e. I nst al l seal s, "O" r i ngs and new bear i ng r aces ( i f r equi r ed) t o bear i ng car r i er and bear i ng adj ust er r i ng. 2) I nstal l and t i ght en bear i ng car r i er t o 111 f t . l bs. ( 150 N. m) . I nst al l l ocki ng t ab. 3) I nstal l bear i ng adj uster r i ng. Ti ght en adj uster r i ng. See Fi g. 51. I f usi ng or i gi nal bear i ngs, t i ght en bear i ng adj uster r i ng t o m ar ks made dur i ng di sass embl y. 4) I f usi ng new bear i ngs, di f f er ent i al or bear i ng car r i er , t i ght en bear i ng adj ust er r i ng t o 37 f t . l bs. ( 50 N. m) . Tur n bear i ng adj uster r i ng 5 l ocki ng l ugs ti ght er . I nst al l l ocki ng t ab. See Fi g. 51. 5) Usi ng I NCH- l b. t orque wr ench, r ot at e t orque wr ench at l east 8 t ur ns t o det ermi ne t ur ni ng t orque. Measur e combi ned t ur ni ng t or que of pi ni on, i nput t r ansf er gear and di f f er ent i al si de r ol l er bear i ngs. See Fi g. 46. See DI FFERENTI AL ROLLER BEARI NG SPECI FI CATI ONS


t abl e. DI FFERENTI AL ROLLER BEARI NG SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Tur ni ng Tor que I ncl udi ng Tr ansf er & Pi ni on Bear i ngs New Bear i ngs . . . . . . . . . . . . . . . . . . . . 33 I NCH Lbs . ( 3. 7 N. m) Used Bear i ngs . . . . . . . . . . . . . . . Same As Bef or e Di sassembl y Di f f er ent i al Si de Bear i ngs Onl y New Bear i ngs . . . . . . . . . . . . . . . . . 5- 7 I NCH Lbs . ( . 6- . 8 N. m) Used Bear i ngs . . . . . . . . . . . . . . . Same As Bef or e Di sassembl y ( 1) - Recor ded dur i ng di sassembl y. See FI NAL DRI VE & TRANSFER GEARS under TRANSAXLE DI SASSEMBLY. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 6) I nstal l ci r cl i ps t o end of each axl e. See Fi g. 52. I nstal l "O" r i ngs and new seal s t o dr i ve axl e f l ange. Fi l l space bet ween seal and dust l i p wi t h mul t i - pur pose gr ease. 7) I nstal l dr i ve axl e f l anges t o t r ansaxl e. I nstal l and t i ght en di f f er ent i al cover bol t s to 21 f t . l bs. ( 28 N. m) . I nstal l speedomet er dr i ve.

Fi g. 51: Pr el oadi ng Di f f er ent i al Si de Bear i ngs Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 52: I ns t al l i ng Ci r c l i ps To Axl es Cour t esy of Vol kswagen Uni t ed St at es, I nc.


TRANSMISSION

NOTE:

Soak al l f r i ct i on- f aced cl ut ch pl at es i n ATF f or at l east 15 mi nut es bef or e i nst al l at i on. Appl y assembl y l ubr i cat i on t o al l bushi ngs, washer s, shi ms and bear i ngs bef ore i nst al l at i on. See Fi g. 17.

1) I nput t r ansf er gear , dr i ve pi ni on and di f f er ent i al assembl i es shoul d be adj ust ed and i nst al l ed at t hi s t i me. I nst al l axi al needl e bear i ng t o i nput t r ansf er gear . See Fi g. 53. I nst al l "O" r i ng and pl anet ar y car r i er . I nst al l washer and axi al needl e bear i ng i nt o pl anet ar y car r i er . See Fi gs. 25 and 54. I nst al l end pl at e shi m f or r ever se br ake cl ut ch pl at es. See Fi g. 55. 2) I nst al l r ever se br ake cl ut ch pl at es. See Fi g. 56. See BRAKE CLUTCH PLATE APPLI CATI ONS t abl e. Usi ng Ass embl y Ri ng( VW 3267) , i nst al l one- way cl ut ch and secur e usi ng ci r cl i p. See Fi gs. 57 and 58. 3) Usi ng a f eel er gauge, check i nst al l ed r ever se br ake cl ut ch cl earance. See Fi g. 59. Cl ear ance shoul d be . 047- . 071" ( 1. 2- 1. 8 mm) . I f cl ear ance i s not as speci f i ed, r epl ace end pl at e shi m. End pl at e shi ms ar e avai l abl e i n t hi cknesses r angi ng f r om . 040" ( 1. 0 mm) t o . 070" ( 1. 9 mm) i n . 004" ( . 10 mm) i ncr ement s.

Fi g. 53: I nst al l i ng Axi al Needl e Bear i ng To I nput Tr ansf er Gear Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 54: I nst al l i ng Pl anet ar y Car r i er & Axi al Needl e Bear i ng Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 55: Expl oded Vi ew Rever se Br ake Cl ut ch Ass embl y Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 56: I nst al l i ng Rever se Br ake Cl ut ch Pl at es Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 57: I nst al l i ng One- Way Cl ut ch Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 58: I ns t al l i ng Ci r c l i ps Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 59: Checki ng Rever se Br ake Cl ut ch Cl ear ance Cour t esy of Vol kswagen Uni t ed St at es, I nc. BRAKE CLUTCH PLATE APPLI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Number Of Pl at es Rever se Cl ut ch I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd- 4t h Cl ut ch I nner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 6


Out er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 4) I nst al l upper ci r cl i p f or suppor t t ube. See Fi g. 58. I nst al l washer and needl e bear i ng i nt o l ar ge sun gear dr i ve shel l . See Fi g. 17. I nst al l l ar ge sun gear dr i ve shel l . See Fi g. 60. 5) I nstal l smal l sun gear dr i ve shel l . I nstal l smal l pl anet ar y dr i ve shaf t wi t h needl e bear i ngs. See Fi gs. 17, 61 and 62. Usi ng a scr ewdr i ver , l ock smal l sun gear dr i ve shel l t o l ar ge sun gear dr i ve shel l . See Fi g. 19. I nst al l adj ust ment shi m, washer and bol t on end of smal l pl anet ar y dr i ve shaf t . Ti ght en bol t t o 22 f t . l bs. ( 30 N. m) . 6) Ensur e end pl ay i s . 009- . 014" ( . 23- . 37 mm) . I f end pl ay i s not as speci f i ed, r echeck assembl y or adj ust ment . See PLANETARY CARRI ER under COMPONENT DI SASSEMBLY & REASSEMBLY.

Fi g. 60: I nst al l i ng Lar ge Sun Gear Dr i ve Shel l Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 61: I nst al l i ng Smal l Sun Gear Dr i ve Shel l Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 62: I nst al l i ng Smal l Pl anet ar y Dr i ve Shaf t Cour t esy of Vol kswagen Uni t ed St at es, I nc. 7) I nst al l bear i ng, washer , and i mpel l er shaf t and 4t h appl y cl ut ch. See Fi g. 63. I nst al l bear i ng, washer and 1st - 3r d appl y cl ut ch wi t h t ur bi ne shaf t assembl y. See Fi g. 64. I nst al l t hr ust shi ms on 1st 3r d appl y cl ut ch housi ng. I nst al l r ever se appl y cl ut ch and suppor t t ube. See Fi g. 65. NOTE:

Tur bi ne shaf t end pl ay was measur ed bef or e di sass embl y. I f end pl ay i s okay, use or i gi nal t hr ust shi ms. I f end pl ay i s not okay or new part s are i nst al l ed, cal cul at e end pl ay and i nst al l r equi r ed t hr ust shi ms.

8) For checki ng pur poses, i nst al l oi l pump gasket and oi l pump. See Fi g. 17. Posi t i on di al i ndi cat or and Suppor t ( VW 387) on t r ansaxl e case. See Fi g. 66. 9) Press di al i ndi cat or on t ur bi ne shaf t , and appl y . 040" ( 1. 0 mm) pr el oad. Move t ur bi ne shaf t up and down. Tur bi ne shaf t end pl ay shoul d be . 019- . 047" ( . 50- 1. 20 mm) . 10) I f end pl ay i s okay, go t o next st ep. I f end pl ay i s not okay, i nst al l r equi r ed t hr ust shi ms. Thr ust shi ms ar e avai l abl e i n t hi cknesses r angi ng f r om . 04" ( 1. 0 mm) t o . 07" ( 1. 8 mm) i n . 008" ( . 20 mm) i ncr ement s. Recheck t ur bi ne shaf t end pl ay. 11) Remove oi l pump and oi l pump gasket . I nst al l suppor t t ube and . 118" ( 3. 0 mm) t hi ck out er spl i ned pl at e f or r ever se appl y cl ut ch. Ensur e gr oove on suppor t t ube engages wedge of one- way cl ut ch. See Fi gs. 17 and 65. 12) I nstal l f r i cti on pl at es and out er spl i ned pl at es f or r ever se appl y cl ut ch i nt o tr ansaxl e case. See Fi g. 67. I nst al l 3 caps and spr i ngs. I nst al l 2nd- 4t h br ake cl ut ch pl at es. See Fi g. 68. See BRAKE CLUTCH PLATE APPLI CATI ONS t abl e. I nst al l 3 spr i ng caps t o spr i ngs.


Fi g. 63: I nst al l i ng 4t h Appl y Cl ut ch & I mpel l er Shaf t Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 64: I nst al l i ng 1st - 3r d Appl y Cl ut ch & Tur bi ne Shaf t Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 65: I nst al l i ng Suppor t Tube Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 66: Checki ng Tur bi ne Shaf t End Pl ay Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 67: I nst al l i ng 2nd- 4t h Br ake Cl ut ch Pl at e & Spr i ngs Cour t esy of Vol kswagen Uni t ed St at es, I nc.


13) DO NOT i nst al l t op out er spl i ned cl ut ch pl at e or waved spr i ng washer . Det ermi ne cl ear ance of 2nd- 4t h br ake cl ut ch. Pr ess 2nd4t h br ake cl ut ch assembl y down. Usi ng a dept h gauge, measur e di st ance f r om t op of oi l pump f l ange t o 2nd- 4t h br ake cl ut ch ( i nner spl i ned) . See Fi g. 69. 14) Pl ace a st r ai ght edge acr oss t op of pi st on. Pl ace gasket on oi l pump f l ange. Usi ng dept h gauge, measur e di st ance f r om st r ai ght edge t o oi l pump f l ange gasket . See Fi g. 70. Subt r act t hi ckness of st r ai ght edge. 15) Subt r act di st ance measured i n st ep 13) f r om di st ance cal cul at ed i n st ep 14) . Thi s gi ves 2nd- 4t h br ake cl ut ch- t o- pi st on di st ance. 16) Subt r act . 140" ( 3. 6 mm) f r om val ue cal cul ated i n st ep 15) . Thi s det er mi nes t hi ckness of l ast out er spl i ned 2nd- 4t h br ake cl ut ch pl at e. Out er spl i ned 2nd- 4t h br ake cl ut ch pl at es ar e avai l abl e i n t hi ckness r angi ng f r om . 080- . 148" ( 2. 00- 3. 75 mm) , i n . 010" ( . 25 mm) i ncr ement s. NOTE:

Manuf act ur er uses . 140" ( 3. 6 mm) val ue t o al l ow f or waved spr i ng washer t hi ckness i nst al l ed wi t h 2nd- 4t h br ake cl ut ch pl at es.

17) I nstal l l ast out er 2nd- 4t h br ake cl ut ch pl at e. I nst al l waved spr i ng washer . I nst al l oi l pump gasket . I nst al l "O" r i ng t o oi l pump, and i nst al l oi l pump. I nst al l cover f or t r ansf er gear s. 18) Move gear change shaf t t o " P" posi t i on. Push manual val ve oper at i ng l ever wi t h manual val ve i nt o val ve body. Ti ght en set scr ew. I nst al l seal i ng pl ug. See Fi gs. 14 and 36. I nst al l val ve body. I nstal l oi l f i l t er scr een and oi l pan. See Fi gs. 14, 71 and 72. I nst al l t or que conver t er .

Fi g. 68: I nst al l i ng 2nd- 4t h Cl ut ch Pl at es Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 69: Measur i ng Oi l Pump Fl ange- To- Cl ut ch Pl at e Cour t esy of Vol kswagen Uni t ed St at es, I nc.

Fi g. 70:

Measur i ng Hei ght Of Pi st on

Fi g. 71: I nst al l i ng Manual Val ve Oper at i ng Lever Cour t esy of Vol kswagen Uni t ed St at es, I nc.


Fi g. 72: I nst al l i ng Val ve Body Cour t esy of Vol kswagen Uni t ed St at es, I nc. TORQUE SPECIFICATIONS

TORQUE SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on Ft. Lbs. ( N. m) Di f f er ent i al Bear i ng Car r i er . . . . . . . . . . . . . . . . . . . 111 ( 150) Di f f er ent i al Hous i ng Cover Bol t s . . . . . . . . . . . . . . . . . 21 ( 28) Dr i ve Axl e Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45) Dr i ve Pi ni on Bear i ng & "O" Ri ng Suppor t . . . . . . . . 148 ( 200) Dr i ve Pi ni on Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 ( 250) I nput Tr ansf er Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . 184 ( 250) Oi l Cool er Banj o Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35) Smal l Pl anet ar y Dr i ve Shaf t Bol t . . . . . . . . . . . . . . . . . 22 ( 30) St ar t er - To- Tr ansaxl e Bol t s . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60) Subf r a me- To- Tr a ns axl e Suppor t Nut . . . . . . . . . . . . . . . . 44 ( 60) Tor que Conver t er Nut s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60) Tr ansaxl e- To- Engi ne Bol t s 10- mm Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60) 12- mm Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80) Tr ansaxl e- To- Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . 44 ( 60) I NCH Lbs. ( N. m) Det ent Spr i ng Scr ews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ( 10) Di f f er ent i al Bear i ng Car r i er / Adj uster Locki ng Tab Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ( 12) Oi l Pan Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ( 12) Oi l Pump- To- Transaxl e Bol t s St ep 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 8) St ep 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Addi t i onal 90 Degr ees Tr ansf er Gear Cover Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . 71 ( 8)


Val ve Body Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 5) Val ve Body Conduct or St r i p Bol t . . . . . . . . . . . . . . . . . . 89 ( 10) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ TRANSMISSION SPECIFICATIONS

TRANSMI SSI ON SPECI FI CATI ONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Appl i cat i on I n. ( mm) Cl ut ch Cl ear ance Appl y Cl ut ches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1) Br ake Cl ut ches 2nd- 4t h . . . . . . . . . . . . . . . . . . . . . ( 2) . 060- . 068 ( 1. 50- 1. 74) Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . 047- . 071 ( 1. 2- 1. 8) Gear & Shaf t End Pl ay Pl anet ar y Car r i er . . . . . . . . . . . . . . . . . . . 009- . 014 ( . 23- . 37) 1st - 3r d To Rever se Appl y Cl ut ch . . . . 019- . 047 ( . 50- 1. 20) Tur bi ne Shaf t . . . . . . . . . . . . . . . . . . . . . . 019- . 047 ( . 50- 1. 20) ( 1) - Assembl ed cl ut ch cl ear ance i s not avai l abl e. ( 2) - See TRANSMI SSI ON under TRANSAXLE REASSEMBLY. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ TECHNICAL SERVICE BULLETINS SHIFTING ERRATIC, HARSH OR DELAYED

1993- On Cabr i o, Gol f , GTI , J et t a & Passat ( Gr oup 01, TSB No. 97- 01, 1- 8- 97) Tr ansaxl e may shi f t er r at i c, har sh or hol d shi f t s t oo l ong ( del ayed upshi f t s) wi t h no t r oubl e codes st or ed i n memory. Thi s condi t i on i s nor mal l y caused by i mpr oper t hr ot t l e angl e set t i ng. I f shi f t i ng qual i t y i s a concer n, per f or m THROTTLE ANGLE SETTI NG pr ocedur e. NOTE:

On a newl y i nst al l ed TCM, basi c set t i ngs must be set pr i or t o per f or mi ng t he f ol l owi ng pr ocedur e. Basi c set t i ngs can be set wi t h Scan Tool ( VAG 1551) usi ng Funct i on " 04" , Di spl ay "OOO" .

Thr ot t l e Angl e Set t i ng 1) Connect scan t ool . Tur n i gni t i on on. Press "1" t o sel ect RAPI D DATA TRANSFER. Ent er addr ess wor d 02 " TRANSMI SSI ON ELECTRONI CS" and advance unt i l " SELECT FUNCTI ON XX" appear s i n scan t ool di spl ay. 2) Press but t ons " 0", t hen "8" t o sel ect f unct i on 08 "READ MEASURI NG VALUE BLOCK" . Pr ess " Q" but t on t o conf i r m i nput . Pr ess " Q" but t on once mor e, t hen ent er gr oup No. 001. Pr ess " Q" but t on t o c onf i r m i nput . 3) Pr i nt screen. Whi l e obser vi ng scan t ool di spl ay, sl owl y pr ess accel er at or pedal unt i l di spl ay r eads 25 per cent . DO NOT rel ease


pedal . Pr i nt screen. 4) Whi l e obser vi ng scan t ool di spl ay, sl owl y pr ess accel er at or pedal unt i l di spl ay r eads 50 per cent . DO NOT rel ease pedal . Pr i nt screen. 5) Whi l e obser vi ng scan t ool di spl ay, sl owl y pr ess accel er at or pedal unt i l di spl ay r eads 75 per cent . DO NOT rel ease pedal . Pr i nt screen. 6) Whi l e obser vi ng scan t ool di spl ay, sl owl y pr ess accel erat or pedal unt i l di spl ay r eads 99 percent . DO NOT r el ease pedal ( r esi st ance of ki ckdown swi t ch shoul d be f el t ) . Pr i nt scr een. 7) Cont i nue pr essi ng accel er at or pedal t o i t s st op whi l e obser vi ng f our t h di gi t on r i ght - si de 8 di gi t di spl ay. Four t h di gi t must change f r om 0 to 1, i ndi cat i ng ki ckdown. Hol d f or 5 seconds t o set t hr ot t l e angl e. 8) Rel ease accel er at or pedal , t hen pr ess r i ght ar r ow but t on on scan t ool . Sel ect f unct i on 06 "END OUTPUT". Repeat procedur e f r om begi nni ng. 9) Compar e vol t age r eadi ngs and t hr ot t l e angl e perc ent ages on pr i nt out f r om f i r st t est wi t h t hat of second t est. I f r eadi ngs do not mat ch, t hr ot t l e angl e was set i ncor r ect l y. 10) I f r eadi ngs do mat ch, r oad t est vehi cl e and act i vat e ki ckdown swi t ch sever al t i mes t o ensur e proper oper at i on. WIRING DIAGRAMS


Fi g. 73: 1995 Tr ansaxl e Wi r i ng Di agr am ( Cabr i o, Gol f & J et t a 2. 0L - Ear l y Pr oducti on)


Fi g. 74: 1995 Tr ansaxl e Wi r i ng Di agr am ( Cabr i o 2. 0L - Lat e Product i on)


Fi g. 75: 1995 Tr ansaxl e Wi r i ng Di agr am ( Gol f & J et t a 2. 0L - Lat e Product i on)


Fi g. 76:

1995 Tr ansaxl e Wi r i ng Di agr am ( J et t a 2. 8L)


Fi g. 77:

1995 Tr ansaxl e Wi r i ng Di agr am ( Passat )


Fi g. 78:

1996 Tr ansaxl e Wi r i ng Di agr am ( Cabr i o)


Fi g. 79: 2. 8L)

1996 Tr ansaxl e Wi r i ng Di agr am ( Gol f 2. 0L & J et t a 2. 0L &

01m Users Manual[1]

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