Page 3 4 Spd. Automatic Transmission 096 00 - General, Technical data Transmission identification Code letters, model/engine applications, ratios, equipment Capacities Repair instructions 01 - On Board Diagnostic (OBD) On Board Diagnostic (OBD), general information Technical data On Board Diagnostic (OBD) program - Guide Electronic component locations On Board Diagnostic (OBD) program VAG 1551 Scan Tool (ST), connecting and selecting functions...
Page 4 Shift mechanism, checking Selector lever cable, checking and adjusting Ignition lock, checking Shift mechanism, disassembling and assembling Selector lever, disassembling and assembling Locking cable, removing and installing Locking cable, adjusting Transmission, checking Shift points, checking Stall speed, checking Main pressure, checking Transmission, removing and installing ATF level ATF level, checking...
Page 5 4th gear clutch -K3- with pump shaft, disassembling and assembling Valve body, removing and installing Valve body conductor strip with transmission fluid temperature sensor, removing and installing Parking lock, disassembling and assembling 39 - Final drive, Differential Oil in final drive, checking Drive flange oil seal, removing and installing Final drive, disassembling and assembling Repair overview...
Page 6 Transmission identification Page 1 of 2 00-1 Transmission identification The 4-speed automatic transmission 096 is installed in the Passat beginning in the 1995 model year. It may be installed in combination with either a 4- cylinder or a 6-cylinder engine. Applications page 00-3 The transmission is identified by type (096), code letters and date of manufacture.
Page 7 Transmission identification Page 2 of 2 00-2 Transmission code letters and date of manufacture (arrow -1-) Example: Transmission Month Year code letters Date (e.g. 3 Jan.,1994) The code letters of the transmission are also listed on the vehicle data plates. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.00.1 12/6/2004...
Page 8 Number of plates Inner Outer Inner Outer Inner Outer Clutch -K1- Clutch -K2- Clutch -K3- Brake -B1- Brake -B2- Application Model Passat 1995 Passat 1995 Engine 2.8 liter - 128 kW 2.0 ltr. - 85 kW (172 hp) (115 hp) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.00.2 12/6/2004...
Page 9 Code letters, model/engine applications, ratios, equipment Page 2 of 2 00-4 Code letters Transmission 1st gear 2.714 :1 2.714 :1 Ratios 2nd gear 1.441 :1 1.441 :1 3rd gear 1.000 :1 1.000 :1 4th gear 0.743 :1 0.743 :1 Reverse gear 2.884 :1 2.884 :1 Intermediate drive No.
Page 10 Capacities Page 1 of 1 00-5 Capacities Planetary gearbox Capacities Planetary Automatic gearbox transmission Initial filling 5.6 liters (5.9 US qt.) Oil change approx. 3.0 liters (3.2 US qt.) Lubricant ATF Dexron Final drive Capacities Final drive Automatic transmission Initial filling 0.75 liter (0.79 US qt.)
Page 11 Repair instructions Page 1 of 4 00-6 Repair instructions 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 carrying out vehicle repairs. A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Repair...
Page 12 Repair instructions Page 2 of 4 00-7 Locking elements Do not overstretch circlips; replace if necessary. Circlips must be properly seated in the grooves. Nuts, bolts Nuts and bolts for attaching covers and housings must be loosened and tightened evenly, in an alternating pattern. Do not distort particularly sensitive parts, e.g.
Page 13 Repair instructions Page 3 of 4 When tapered roller bearings are mounted on a shaft, always replace them together and use bearings from the same manufacturer. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.00.4 12/6/2004...
Page 14 Repair instructions Page 4 of 4 00-8 Shims Measure shims at several points with a micrometer. Different tolerances in shims of the same nominal size make it possible to obtain the exact shim thickness required. Check for signs of burrs and damage. Only install shims that are in perfect condition.
Page 15 On Board Diagnostic (OBD), general information Page 1 of 19 01-1 On Board Diagnostic (OBD), general information Function The 096 automatic transmission is controlled electro-hydraulically. "On Board Diagnostic" capability refers specifically to the electrical and electronic controls. The Transmission Control Module (TCM) -J217- receives input signals from components that effect gear selection, and sends output signals to solenoid valves that control gear selection in the...
Page 16 On Board Diagnostic (OBD), general information Page 2 of 19 01-2 Electrical malfunctions that affect vehicle performance can be identified using the VAG 1551 Scan Tool (ST). The On Board Diagnostic (OBD) capabilities can only be fully exploited using operating mode 1 ("Rapid data transfer"). Functions of the VAG 1551 Scan Tool (ST) List of selectable functions, page 01-24 Safety functions of the Transmission Control...
Page 17 On Board Diagnostic (OBD), general information Page 3 of 19 01-3 Malfunctions that may activate emergency running mode: Open circuit in wiring, short-circuit, malfunctions in electrical or hydraulic components. Transmission Control Module (TCM) recognition of malfunctions If a malfunction exists for a certain time, it is stored as a static malfunction.
Page 18 On Board Diagnostic (OBD), general information Page 4 of 19 01-4 Technical data Memory Permanent memory Volatile memory Data output Rapid data transfer Blink-code output Output Diagnostic Test Mode (DTM) Basic setting Transmission Control Module (TCM) coding Reading measured value block ((VAG 1551 function 08) Component locations page...
Page 19 On Board Diagnostic (OBD), general information Page 5 of 19 01-5 On Board Diagnostic (OBD) program - Guide Troubleshooting Automatic Transmission with VAG 1551 Scan Tool (ST) Connect VAG 1551 Scan Tool (ST) and select 1- Rapid data transfer Enter address word 02 Transmission electronics Check control module identification Check DTC Memory (function 02) No DTC recognized...
Page 20 On Board Diagnostic (OBD), general information Page 6 of 19 01-6 Check wiring according to wiring diagrams Electrical Wiring Diagrams, Troubleshooting and Component Locations binder Check DTC Memory (function Replace component Erase DTC Memory (function Initiate basic setting (function Carry out road test Check DTC Memory again (function 02) If No DTC recognized! is indicated on display the On Board Diagnostic program has been...
Page 21: Table Of Contents
On Board Diagnostic (OBD), general information Page 7 of 19 01-7 Electronic component locations Note: If the Engine Control Module (ECM) or Transmission Control Module (TCM) -J217- is replaced, the system must be brought to basic setting Basic setting, initiating, page 01-39 1 - Transmission Control Module (TCM) -J217-...
Page 22 On Board Diagnostic (OBD), general information Page 8 of 19 01-8 3 - Data Link Connector (DLC) Location: right-hand side of instrument cluster page 01-20 4 - Valve body Location Fig. 4 Removing/installing page 38-22 The Solenoid Valves - N88-, -N89-, -N90-, - N91-, -N92-, -N93-, - N94- and the Transmission Fluid...
Page 23: Location, Removing And Installing Fig
On Board Diagnostic (OBD), general information Page 9 of 19 01-9 5 - Multi-Function Transmission Range (TR) Switch -F125- Location, removing and installing Fig. 5 Checked by On Board Diagnostic (OBD) program 6 - Vehicle Speed Sensor (VSS) -G68- Location, removing and installing Fig.
Page 24: Engine Control Module
On Board Diagnostic (OBD), general information Page 10 of 19 01-10 7 - Throttle Position (TP) Sensor -G69- Location Fig. 7 Removing and installing: Repair Manual, Fuel Injection & Ignition, Repair Group 24 Various types according to engine version Signal checked by On Board Diagnostic (OBD) program Vehicles from 01.93...
Page 25 On Board Diagnostic (OBD), general information Page 11 of 19 01-11 8 - Shiftlock Solenoid - N110- Location Fig. 8 Removing and installing page 37-1 Can be checked electrically page 01- and by reading measured value block page 01-40 9 - Cruise Control Switch - E45- Location Fig.
Page 26 On Board Diagnostic (OBD), general information Page 12 of 19 01-12 11 - Brake Light Switch -F- Location Fig. 11 Removing and installing Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 47 Can be checked electrically page 01- and via reading measured value block page 01-40 12 - Park/Neutral Position...
Page 27 On Board Diagnostic (OBD), general information Page 13 of 19 01-13 Fig. 1 Transmission Control Module (TCM) - J217- Location: From 01.93 the Transmission Control Module (TCM) is located under the rear seat. Transmission Control Module -J217- (TCM), removing and installing (TCM with 38-pin connector) - Fold up rear seat.
Page 28 On Board Diagnostic (OBD), general information Page 14 of 19 01-14 Fig. 2 Transmission Control Module -J217- (TCM) with 68-pin connector, removing - Release multi-pin connector lock, then disconnect multi-pin connector. - Remove TCM. Fig. 3 Transmission Control Module -J217- (TCM) with 68-pin connector, installing - Place multi-pin connector in position on control module locating pins (arrows), then lock multi-pin...
Page 29 On Board Diagnostic (OBD), general information Page 15 of 19 01-15 Fig. 4 Valve body Location: The valve body is located inside the transmission, mounted above the ATF oil pan. Solenoid Valves -N88-, -N89-, -N90-, -N91-, -N92-, - N93-, -N94- and Transmission Fluid Temperature Sensor -G93- are attached to the valve body.
Page 30 On Board Diagnostic (OBD), general information Page 16 of 19 01-16 Fig. 6 Vehicle Speed Sensor (VSS) -G68- Location: The Vehicle Speed Sensor (VSS) is located on top of the transmission. Removing and installing Vehicle Speed Sensor - Disconnect harness connector from sensor. - Remove retaining bolt and pull out sensor.
Page 31 On Board Diagnostic (OBD), general information Page 17 of 19 01-17 Fig. 8 Shiftlock Solenoid -N110- Location: The Shiftlock Solenoid is located on the gear selector lever. Removing and installing Shiftlock Solenoid page 37-1 Fig. 9 Cruise Control Switch -E45- Location: The Cruise Control Switch is located on the steering column switch.
Page 32 On Board Diagnostic (OBD), general information Page 18 of 19 01-18 Fig. 10 Kickdown Switch -F8- Location: The Kickdown Switch (arrow) is integrated with the Accelerator Pedal cable and is located on the bulkhead in the engine compartment. Removing and installing Kickdown Switch - Disconnect Accelerator Pedal cable to remove and install Kickdown Switch, then reinstall cable and adjust.
Page 33 On Board Diagnostic (OBD), general information Page 19 of 19 01-19 Fig. 12 Park/Neutral Position (PNP) Relay - J226- Location: The PNP Relay is located on the auxiliary relay panel under the instrument panel, left side. Marked with number "150" (arrow) Fig.
Page 34 On Board Diagnostic (OBD) program Page 1 of 43 01-20 On Board Diagnostic (OBD) program VAG 1551 Scan Tool (ST), connecting and selecting functions Test conditions: Battery Positive Voltage (B+) OK Fuses 14 (S14) and 21 (S21) OK Transmission Ground (GND) connections - Check Ground connections for corrosion and poor contact;...
Page 35 On Board Diagnostic (OBD) program Page 2 of 43 01-21 Indicated on display: VAG - ON BOARD DIAGNOSTIC HELP 1 - Rapid data transfer 1) Operating modes -1- and -2- are displayed 2 - Blink code output 1) alternately Notes: Additional operating instructions can be printed out by pressing the HELP button on the VAG 1551 Scan Tool.
Page 36 On Board Diagnostic (OBD) program Page 3 of 43 01-22 Indicated on display: Rapid data transfer 02 Transmission electronics - Press -Q- button to confirm input. Indicated on display: 096927731AD AG4 Gearbox 096 1283 Coding 00000 WSC 131071 The Transmission Control Module (TCM) identification, TCM coding and VAG 1551 Scan Tool dealership number are displayed.
Page 37 On Board Diagnostic (OBD) program Page 4 of 43 01-23 Indicated on display: Control module does not answer! HELP - A list of possible malfunction causes can be printed out by pressing the HELP button. - After eliminating possible causes of malfunctions, again enter the address word 02 for "Transmission Electronics"...
Page 38 On Board Diagnostic (OBD) program Page 5 of 43 01-24 List of selectable functions Function Page Check Transmission Control Page Module version On Board 01-20 Diagnostic (OBD) program Check DTC Memory Page 01-25 Initiate basic setting Page 01-39 Erase DTC Memory Page 01-37 End output...
Page 39 On Board Diagnostic (OBD) program Page 6 of 43 01-25 Diagnostic Trouble Code (DTC) Memory, checking - Connect VAG 1551 Scan Tool and enter address word 02 for "Transmission Electronics" and advance until "Select function XX" appears in display from page 01-20 Indicated on display: Rapid data transfer HELP...
Page 40 On Board Diagnostic (OBD) program Page 7 of 43 01-26 Diagnostic Trouble Code (DTC) table Note: Malfunctions are recognized by the Transmission Control Module (TCM) -J217-, displayed by the VAG 1551 ScanTool (ST) and printed (with the printer switched ON) when the Diagnostic Trouble Code (DTC) Memory is checked.
Page 41 On Board Diagnostic (OBD) program Page 8 of 43 01-27 VAG 1551 print-out Possible cause of Repairing malfunction malfunction 00258 Open circuit or short to - Check wiring and connections according to Ground (GND) wiring diagram Solenoid Valve 1 - Solenoid Valve 1 -N88- - Read measured value block page 01-40...
Page 42 On Board Diagnostic (OBD) program Page 9 of 43 01-28 VAG 1551 print-out Possible cause of Repairing malfunction malfunction 00264 Open circuit or short to - Check wiring and connections according to Ground (GND) wiring diagram Solenoid Valve 4 - Solenoid Valve 4 -N91- - Read measured value block page 01-40...
Page 43 On Board Diagnostic (OBD) program Page 10 of 43 01-29 VAG 1551 print-out Possible cause of malfunction Repairing malfunction 00270 Open circuit or short to Ground - Check wiring and connections according (GND) to wiring diagram Solenoid Valve 7 - Solenoid Valve 7 -N94- - Read measured value block page 01-...
Page 44 On Board Diagnostic (OBD) program Page 11 of 43 01-30 VAG 1551 print-out Possible cause of malfunction Repairing malfunction 00293 Open circuit in wiring - Check wiring and connections according to wiring diagram Multi-Function TR Multi-Function Transmission Range - Read measured value block Switch -F125- (TR) Switch -F125- malfunctioning page 01-40...
Page 45 On Board Diagnostic (OBD) program Page 12 of 43 01-31 VAG 1551 print- Possible cause of malfunction Repairing malfunction 00518 Open or short circuit - If DTC 00638 is also displayed, then repair this first - Check wiring and connections according to wiring diagram Throttle Position Throttle Position (TP) Sensor -G69- malfunctioning...
Page 46 On Board Diagnostic (OBD) program Page 13 of 43 01-32 VAG 1551 print-out Possible cause of Repairing malfunction malfunction 00529 Open circuit in wiring - Check wiring and connections according to wiring diagram RPM information - Read measured value block page 01-40 missing display group number 03...
Page 47 On Board Diagnostic (OBD) program Page 14 of 43 01-33 VAG 1551 print-out Possible cause of malfunction Repairing malfunction 00545 Open circuit or short to Ground (GND) - Check wiring and connections according to wiring diagram Engine/trans. No connection between Engine Control - Read measured value block electrical connection Module (ECM) and Transmission...
Page 48 On Board Diagnostic (OBD) program Page 15 of 43 01-34 VAG 1551 print-out Possible cause of malfunction Repairing malfunction 00638 Open circuit or short to Ground (GND) - Check wiring and connections according to wiring diagram Engine/trans. No connection between Engine Control - Read measured value block electrical Module (ECM) and Transmission Control...
Page 49 On Board Diagnostic (OBD) program Page 16 of 43 01-35 VAG 1551 print-out Possible cause of Repairing malfunction malfunction 00652 Electrical/hydraulic - Read measured value block page 01-40 malfunction display group number 04 and determine gear in which malfunction occurs Transmission range Clutch or valve body controller...
Page 50 On Board Diagnostic (OBD) program Page 17 of 43 01-36 VAG 1551 print-out Possible cause of malfunction Repairing malfunction 65535 - Replace Transmission Control Module (TCM) -J217- page 01-7 Transmission Control Module - Bring system into basic settings (TCM) -J217- malfunctioning Control Module page 01-39 malfunctioning...
Page 51 On Board Diagnostic (OBD) program Page 18 of 43 01-37 Diagnostic Trouble Code (DTC) Memory, erasing Requirement: DTC Memory checked page 01-25 After DTC Memory has been checked: Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -5- (to select function 05, "Erase DTC Memory").
Page 52 On Board Diagnostic (OBD) program Page 19 of 43 01-38 Indicated on display: Rapid data transfer DTC Memory is erased (DTC Memory will be erased approx. 5 seconds after the message is displayed.) DTC Memory is now erased. Note: Wait about 1 minute before checking DTC Memory again.
Page 53 On Board Diagnostic (OBD) program Page 20 of 43 01-39 Basic setting, initiating Note: The basic setting should be initiated after performing the following repairs: Replacing engine Replacing Engine Control Module (ECM) Replacing or altering throttle valve Adjusting throttle valve (setting idle speed). Replacing Throttle Position (TP) Sensor - G69- Altering setting of Throttle Position (TP) Sensor...
Page 54 On Board Diagnostic (OBD) program Page 21 of 43 01-40 Indicated on display: Rapid data transfer 04 Basic setting - Press -Q- button to confirm input. Indicated on display: Basic setting HELP Input display group number XX - Press button -0- twice (to input display group 00). - Press -Q- button to confirm input.
Page 55 On Board Diagnostic (OBD) program Page 22 of 43 01-41 Indicated on display: Rapid data transfer 08 - Read measuring value block - Press -Q- button to confirm input. Indicated on display: Read measuring value block Input display group number XX - Enter display group number List of selectable display groups, page 01-42...
Page 56 On Board Diagnostic (OBD) program Page 23 of 43 01-42 List of selectable display groups Display group No. 01 Display group No. 02 Display group No. 03 Display group No. 04 Display group No. 05 Display Display Designation Reading measured value block group No.
Page 57 On Board Diagnostic (OBD) program Page 24 of 43 Selector lever position Vehicle speed Transmission fluid (ATF) temperature Switch output Gear to select Engine speed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.2 12/6/2004...
Page 58 On Board Diagnostic (OBD) program Page 25 of 43 01-43 Notes: Reading measured value block 4 If the printer is switched ON, the current display is 1001 00 0 P 0 km/h printed out on the log. If the values in all the display fields are as specified: - Press button Indicated on display:...
Page 59 On Board Diagnostic (OBD) program Page 26 of 43 01-44 Test table Display Display Designation Test Specified Repairing Group field conditions display on malfunction VAG 1551 Selector lever Stationary - Check Multi-Function position - Multi- Transmission Range Function Transmission (TR) Switch -F125-: Range (TR) Switch - Carry out electrical F125-...
Page 60 On Board Diagnostic (OBD) program Page 27 of 43 01-45 Display Display Designation Test conditions Specified Repairing malfunction Group field display on VAG 1551 Voltage of Stationary Idling - 0.156 V When accelerating from Throttle Position min. idle to Wide Open Throttle, (TP) Sensor - voltage value increases G69-...
Page 61 On Board Diagnostic (OBD) program Page 28 of 43 cont'd Engine with Mono-Motronic: Engine Coolant Temperature (ECT) min. 80 C (176 F). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.2 12/6/2004...
Page 62 On Board Diagnostic (OBD) program Page 29 of 43 01-46 Display Display Designation Test conditions Specified Repairing Group field display on malfunction VAG 1551 Accelerator Pedal Stationary Idling 0-1% When accelerating value from idle to Wide Open Throttle, percent (%) value increases constantly Wide...
Page 63 On Board Diagnostic (OBD) program Page 30 of 43 01-47 Display Display Designation Test conditions Specified Repairing Group field display on malfunction VAG 1551 Kick Down Display Operated - Check Kick Down Switch -F8- Switch -F8-: Carry out electrical tests from page 01-59 operated Multi-...
Page 64 On Board Diagnostic (OBD) program Page 31 of 43 01-48 Display Display Designation Test conditions Specified Repairing malfunction Group field display on VAG 1551 Actual current of Stationary - Check Solenoid Valve - Solenoid Valve 6 N93-: Carry out -N93- Wide 0.0 A electrical tests...
Page 65 On Board Diagnostic (OBD) program Page 32 of 43 01-49 Display Display Designation Test conditions Specified Repairing malfunction Group field display on VAG 1551 Vehicle speed Driving km/h Speedometer reading and VAG 1551 Scan Tool (ST) display may differ slightly Engine Speed With engine running - Tune engine if...
Page 66 On Board Diagnostic (OBD) program Page 33 of 43 01-50 Display Display Designation Test conditions Specified Repairing malfunction Group field display on VAG 1551 Accelerator Driving When accelerating from Pedal value idle to Wide Open Throttle, percent (%) Idle 0-1% value increases constantly - Bring system into...
Page 67 On Board Diagnostic (OBD) program Page 34 of 43 01-51 Reading measured value block, display group 04 - Checking Solenoid Valves while driving The Solenoid Valves can be checked while driving with the "Read measuring value block" function (08), display group number 04. The table shows how the Solenoid Valves -N88-, -N89-, -N90- and -N91- are controlled in each selector lever position.
Page 68 On Board Diagnostic (OBD) program Page 35 of 43 01-52 Display Display Designation Test conditions Specified Repairing Group field display on malfunction if not to VAG 1551 specification Selector lever Solenoid Valve Solenoid Valves are 1 0 0 1 00 activation indicated selected according to by VAG 1551...
Page 69 On Board Diagnostic (OBD) program Page 36 of 43 0 0 0 1 00 While driving with drive gear selected a second technician is needed for reading the specified values. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.2 12/6/2004...
Page 70 On Board Diagnostic (OBD) program Page 37 of 43 01-53 Display Display Designation Test conditions Specified Repairing Group No. field display on VAG malfunction 1551 Gear Driving - Check Solenoid selected Valves Neutral electrical tests, from page 01-59 Reverse 1 hydraulic 2 hydraulic 3 hydraulic cont'd...
Page 71 On Board Diagnostic (OBD) program Page 38 of 43 01-54 Display Display Designation Test Specified Repairing malfunction Group field conditions display on VAG 1551 Selector lever Driving - Check Multi-Function Transmission Range (TR) position Switch -F125- electrical tests, from page 01-59 Vehicle Speed at which...
Page 72 On Board Diagnostic (OBD) program Page 39 of 43 01-55 Display Display Designation Test conditions Specified Repairing Group field display on malfunction VAG 1551 Transmission fluid Stationary with - Check Transmission (ATF) temperature engine running. Fluid Temperature Sensor -G93- is checked at Exact approx.
Page 73 On Board Diagnostic (OBD) program Page 40 of 43 While driving with drive gear selected a second technician is needed for reading the specified values http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.2 12/6/2004...
Page 74: Display 1 Is
On Board Diagnostic (OBD) program Page 41 of 43 01-56 Display Display Designation Test Specified Repairing malfunction Group field conditions display on VAG 1551 Selector Shiftlock - Check wiring according to outputs Solenoid - wiring diagram N110- - Check Shiftlock Solenoid -N110- electrical tests, from page 01-59...
Page 75 On Board Diagnostic (OBD) program Page 42 of 43 01-57 Display Display Designation Test Specified display Repairing malfunction Group No. field conditions on VAG 1551 Display 6 Air conditioner - Check routing of wiring switched off according to wiring diagram was not - Check air conditioner switched off...
Page 76: Repair Manual, 2.0
On Board Diagnostic (OBD) program Page 43 of 43 01-58 Display Display Designation Test conditions Specified Repairing malfunction Group field display on VAG 1551 Gear to select Driving Neutral - Check Solenoid Valves: Carry out electrical tests from page 01-59 Reverse 1 hydraulic - If no gearshifts are...
Page 77 Transmission electrical testing Page 1 of 33 01-59 Transmission electrical testing Test requirements: Battery Positive Voltage (B+) OK Fuses 14 (S14) and 21 (S21) OK Transmission Ground (GND) connections Ground (GND) connection located on left next to relay panel - Check Ground connections for corrosion and poor contact;...
Page 78 Transmission electrical testing Page 2 of 33 01-60 Note: Use the hand multimeter (Fluke 83, VAG 1526 or equivalent)for testing. Use auxiliary cables from the VAG 1594 adapter kit, and the test box as specified, for connecting test equipment. The specified values are valid for ambient temperatures ranging from 0-40 C (32-104 F).
Page 79 Transmission electrical testing Page 3 of 33 01-61 Electrical testing on Transmission Control Module (TCM) with 38-pin connector The Transmission Control Module (TCM) -J217- is located under the rear seat. Wiring from the 38-pin TCM connector can be checked according to the wiring diagram using the VAG 1598 test box.
Page 80 Transmission electrical testing Page 4 of 33 01-62 Terminal assignment for 38-pin Transmission Control Module (TCM) -J217- connector(also sockets on VAG 1598 test box) 1- Ground (GND) (terminal 31) 20- Shiftlock Solenoid -N110- 2- Solenoid Valve 4 -N91- 21- Solenoid Valve 7 -N94- 3- Solenoid Valve 3 -N90- 22- Solenoid Valve 1 -N88- 4- Not assigned...
Page 81 Transmission electrical testing Page 5 of 33 19- Battery Positive Voltage (B+) (terminal 15) 38- Cruise Control system Voltage supply (contacts 10 and 29) not assigned on vehicles with 6-cylinder engine; Throttle Position (TP) Sensor signal (terminal 9) is routed to the Transmission Control Module (TCM) via the Motronic Engine Control Module (ECM).
Page 82 Transmission electrical testing Page 6 of 33 01-63 List of test steps (TCM with 38-pin connector) Note: Only carry out test steps listed in Diagnostic Trouble Code (DTC) table, or referred to while reading measured value block. Component checked Component checked Battery Positive Voltage (B+) supply from Solenoid Valve 5 -N92- - Carry out...
Page 83 Transmission electrical testing Page 7 of 33 01-64 Test table Switch to voltage measuring range 20 V Test VAG 1598 Test of Specified Repairing Test step sockets value malfunction conditions - Additional operations 19 + 1 Supply voltage from approx. Battery Ignition - Check wiring Transmission Control...
Page 84: Fuel Injection & Ignition, Repair Group
Transmission electrical testing Page 8 of 33 01-65 Switch to voltage measuring range 20 V Test VAG 1598 Test of Specified Repairing malfunction Test conditions step sockets value - Additional operations 10 + 29 Throttle 4.6 to 5 V Ignition switched - Check routing of wiring Position according to wiring...
Page 85 Transmission electrical testing Page 9 of 33 Not checked on vehicles with 6-cylinder engine; Signal from TP Sensor -G69- is directed to TCM via ECM and can only be measured by the "Reading measured value block" function using the VAG 1551 Scan Tool page 01-40 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3...
Page 86: J217
Transmission electrical testing Page 10 of 33 01-66 Switch to voltage measuring range 20 V Test VAG 1598 Test of Specified Repairing malfunction Test conditions step sockets value - Additional operations 19 + 20 Shiftlock approx. Battery Ignition - Check wiring according to Solenoid - Positive Voltage switched ON...
Page 87 Transmission electrical testing Page 11 of 33 01-67 Switch to voltage measuring range 20 V Test VAG 1598 Test of Specified Repairing malfunction Test step sockets value conditions - Additional operations 34 + 1 Multi-Function 4.5 to 5 V Ignition - Check wiring Transmission switched ON...
Page 88 Transmission electrical testing Page 12 of 33 0 to 0.8 V - Selector lever positions D, 3, 2 and 1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3 12/6/2004...
Page 89 Transmission electrical testing Page 13 of 33 01-68 Switch to resistance measuring range 200 Test VAG 1598 Test of Specified Repairing Test conditions step sockets value malfunction - Additional operations 22 + 18 Solenoid 55 to 65 - Check routing of Ignition switched OFF Valve 1 - wiring according to...
Page 90 Transmission electrical testing Page 14 of 33 01-69 Switch to resistance measuring range 200 Test VAG 1598 Test of Specified Repairing Test conditions step sockets value malfunction - Additional operations 24 + 18 Solenoid 55 to 65 - Check routing of Ignition switched OFF Valve 5 - wiring according to...
Page 91 Transmission electrical testing Page 15 of 33 01-70 Switch to resistance measuring range 200 Test VAG 1598 Test of Specified Repairing malfunction Test conditions step sockets value - Additional operations 19 + 20 Shiftlock 14 to 25 - Check routing of wiring Ignition switched OFF Solenoid - according to wiring...
Page 92 Transmission electrical testing Page 16 of 33 01-71 Switch to resistance measuring range 20 K Test VAG 1598 Test of Specified Repairing malfunction Test conditions step sockets value - Additional operations 32 + 33 Vehicle Ignition switched - Check wiring according Speed to wiring diagram Sensor...
Page 93 Transmission electrical testing Page 17 of 33 01-72 Switch to resistance measuring range 2 M Test VAG 1598 Test of Specified Repairing Test conditions step sockets value malfunction - Additional operations 30 + 18 Transmission Fluid - Check wiring Ignition switched OFF Temperature Sensor according to -G93- (ATF)
Page 94 Transmission electrical testing Page 18 of 33 01-73 Electrical testing on Transmission Control Module (TCM) with 68-pin connector Test requirements, Cautions, notes page 01-59 The Transmission Control Module (TCM) -J217- is located under the rear seat. - Switch ignition off, release multi-pin connector lock in direction of -arrow-, then disconnect from control module.
Page 95 Transmission electrical testing Page 19 of 33 01-74 After electrical checks: - Re-connect multi-pin connector to TCM and lock. Note: When re-connecting, make sure that the guides (arrows) are engaged with the TCM pins. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3 12/6/2004...
Page 96 Transmission electrical testing Page 20 of 33 01-75 Terminal assignment for 68-pin Transmission Control Module (TCM) -J217- connector(also sockets on VAG 1598/18 test box) 1- Ground (GND) (terminal 31) 19- Engine TD-signal (RPM) 2- Not assigned 20- Vehicle Speed Sensor -G68- 3- Not assigned 21- Not assigned 4- Not assigned...
Page 97 Transmission electrical testing Page 21 of 33 Signal contacts (5 and and regulated voltage supply contact ( not assigned on vehicles with 6- cylinder engine; Load signal (contact is directed to Transmission Control Module (TCM) via Motronic Engine Control Module (ECM) and can only be checked using the "Reading measured value block" function of the VAG 1551 Scan Tool (ST) page 01-40 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3...
Page 98 Transmission electrical testing Page 22 of 33 01-76 37- Not assigned 53- Not assigned 38- Not assigned 54- Solenoid Valve 2 -N89- 39- Not assigned (by VW) 55- Solenoid Valve 1 -N88- 40- Multi-function Transmission Range (TR) 56- Solenoid Valve 5 -N92- Switch -F125- 41- Load signal from Motronic Engine Control 57- Selector lever display...
Page 99 Transmission electrical testing Page 23 of 33 01-77 List of test steps (TCM with 68-pin connector) Note: Only carry out test steps as listed in Diagnostic Trouble Code (DTC) table, or referred to while reading measured value block. Component checked Component checked Battery Positive Voltage (B+) supply from Solenoid Valve 5 -N92-...
Page 100 Transmission electrical testing Page 24 of 33 01-78 Test table Switch to voltage measuring range 20 V Test Test of Specified Repairing malfunction Test step 1598/18 value conditions sockets - Additional operations 23 + 1 Supply voltage from approx. Ignition - Check wiring Transmission Control Battery...
Page 101 Transmission electrical testing Page 25 of 33 Positive Voltage (B+) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3 12/6/2004...
Page 102 Transmission electrical testing Page 26 of 33 01-79 Switch to resistance measuring range 20 K Test Test of Specified Repairing malfunction Test step 1598/18 value conditions sockets - Additional operations 5 + 28 Throttle Ignition - Check wiring according to wiring Position (TP) switched diagram...
Page 103 Transmission electrical testing Page 27 of 33 - min. 2.1 K - max. 3.9 K Wide Open Throttle - min. 0.7 K - max. 1.8 K Engine with Mono Motronic: Engine Coolant Temperature (ECT) min. 80 C (176 F). Not checked on vehicles with 6-cylinder engine; Signal from TP Sensor -G69- is directed to TCM via ECM and can only be measured using the "Reading measured value block"...
Page 104 Transmission electrical testing Page 28 of 33 01-80 Switch to resistance measuring range 200 Test Test of Specified Repairing malfunction Test step 1598/18 value conditions sockets - Additional operations 63 + 1 Multi-Function infinite - Selector lever - Check wiring according Transmission positions R, N, D, to wiring diagram...
Page 105 Transmission electrical testing Page 29 of 33 - Selector lever positions D, 3, 2 and 1 Switch multimeter to largest (ohms) range http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.3 12/6/2004...
Page 106 Transmission electrical testing Page 30 of 33 01-81 Switch to resistance measuring range 200 Test Test of Specified Repairing malfunction Test conditions step 1598/18 value sockets - Additional operations 55 + 67 Solenoid Valve 55 to 65 Ignition - Check routing of wiring 1 -N88- switched OFF according to wiring...
Page 107 Transmission electrical testing Page 31 of 33 01-82 Switch to resistance measuring range 200 Test Test of Specified Repairing malfunction Test conditions step 1598/18 value sockets - Additional operations 56 + 67 Solenoid Valve 5 55 to 65 Ignition - Check routing of wiring -N92- switched OFF according to wiring...
Page 108 Transmission electrical testing Page 32 of 33 01-83 Switch to resistance measuring range 200 Test Test of Specified Repairing malfunction Test conditions step 1598/18 value sockets - Additional operations 1 + 16 Kick Down infinite Ignition switched - Check routing of wiring Switch -F8- according to wiring diagram...
Page 109 Transmission electrical testing Page 33 of 33 01-84 Switch to resistance measuring range 2 M Test Test of Specified Repairing Test conditions step 1598/18 value malfunction sockets - Additional operations 6 + 67 Transmission Fluid Ignition switched - Check wiring Temperature Sensor - according to wiring G93- (ATF)
Page 110 Torque converter Page 1 of 4 32-1 Torque converter The ATF pump is driven via the torque converter. When installing the torque converter, make sure that both drive pins engage in the recesses in the ATF pump inner wheel. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.32.1 12/6/2004...
Page 111 Torque converter Page 2 of 4 32-2 Torque converter, identifying There are various torque converters. They are identified by code letters -arrow-. Transmission/torque converter applications tables starting page 00-3 Torque converter code letters (Transmission installed) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.32.1 12/6/2004...
Page 112 Torque converter Page 3 of 4 32-3 Torque converter, draining If the torque converter has become contaminated by particles resulting from wear or abrasion, or when carrying out a major overhaul of the transmission, drain the torque converter as follows: - Extract automatic transmission fluid (ATF) from torque converter using VAG 1358A with VAG 1358 A/1 probe, or EZ1 fluid evacuator.
Page 113 Torque converter Page 4 of 4 32-4 Torque converter oil seal, removing and installing Removing torque converter oil seal Installing torque converter oil seal - Drive in seal until flush. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.32.1 12/6/2004...
Page 114 Shift mechanism, servicing Page 1 of 25 37-1 Shift mechanism, servicing CAUTION! Before working on the engine when it is running, move the transmission selector lever into the "P" position and apply the parking brake. Shift mechanism, checking Selector lever in "P" position; ignition switched ON Brake pedal not depressed: Selector lever is locked and cannot be shifted...
Page 115 Shift mechanism, servicing Page 2 of 25 37-2 Selector lever in "N" position and ignition switched ON: Brake pedal not depressed: Selector lever is locked and cannot be shifted out of "N" position. Shiftlock Solenoid -N110- blocks selector lever. Brake pedal depressed: Shiftlock Solenoid -N110- releases selector lever.
Page 116 Shift mechanism, servicing Page 3 of 25 37-3 Selector lever cable, checking and adjusting Checking - Remove selector lever cable combi-bolt from lever/selector shaft. - Move selector lever from "P" to "1." Shift mechanism and selector lever cable must move freely. If necessary replace selector lever cable or service shift mechanism.
Page 117 Shift mechanism, servicing Page 4 of 25 37-4 Ignition lock, checking - Shift selector lever to "P" position and turn ignition key to end ("OFF") position. It must only be possible to remove ignition key with selector lever in "P" position. - Remove ignition key.
Page 118 Shift mechanism, servicing Page 5 of 25 37-5 Shift mechanism, disassembling and assembling 1 - Ignition/Starter Switch 2 - Locking cable Must not be kinked Adjusting page 37- Removing and installing page 37- 3 - Clip For securing locking cable Always replace 4 - Selector lever handle 5 - Set screw...
Page 119 Shift mechanism, servicing Page 6 of 25 37-6 9 - Selector lever Disassembling and assembling page 37-13 To remove selector lever, lower protective plate is removed and front protective plate is removed and pushed forward When installing selector lever, insert locking cable anchor in notch of selector lever housing...
Page 120 Shift mechanism, servicing Page 7 of 25 37-7 10 - Nuts To secure center console 11 - Spacer 12 - Gasket Always replace 13 - Selector lever housing Need not be removed to replace selector lever cable or individual parts of shift mechanism Removing and installing...
Page 121 Shift mechanism, servicing Page 8 of 25 37-8 15 - Nut Tightening torque: 15 Nm (11 ft lb) Always replace Qty. 3 16 - Protective sleeve Insert into selector lever housing before attaching selector lever cable 17 - Hex nut With shoulder Tightening torque: 25 Nm (18 ft lb)
Page 122 Shift mechanism, servicing Page 9 of 25 37-9 18 - Selector lever cable To remove selector lever, lower protective plate is removed, exhaust system is separated in front of Three Way Catalytic Converter (TWC) and front protective plate removed (vehicles with 6-cyl.
Page 123 Shift mechanism, servicing Page 10 of 25 37-10 19 - Seal Bonded to cable anchor Replace if damaged 20 - Circlip Install after installing selector lever cable Fig. 3 21 - Washer 22 - Bolt 23 - Transmission 24 - Lever For selector shaft 25 - Bracket With cable anchor for...
Page 124 Shift mechanism, servicing Page 11 of 25 37-11 Fig. 1 Removing and installing selector lever housing - Remove rear center console. - Remove hex nut with shoulder. - Remove lower protective plate. - Disconnect Oxygen Sensor connector, separate exhaust system in front of Three Way Catalytic Converter (TWC).
Page 125 Shift mechanism, servicing Page 12 of 25 37-12 Fig. 3 Attaching selector lever cable to selector lever - Fit selector lever cable eye (arrow) onto selector lever and secure with circlip. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.1 12/6/2004...
Page 126 Shift mechanism, servicing Page 13 of 25 37-13 Selector lever, disassembling and assembling Note: Selector lever must be removed to replace individual parts page 37-6 , item - 9 -. 1 - Selector lever Assembling Fig. 1 2 - Indicator lighting Mounting indicator lighting connector Fig.
Page 127 Shift mechanism, servicing Page 14 of 25 37-14 5 - Guide sleeve Fit after installing push 6 - Set screw Always replace To remove, first remove Shiftlock Solenoid and indicator lighting -2-. Clamp set screw in vice and loosen by turning selector lever Install with thread- locking fluid AMV185...
Page 128 Shift mechanism, servicing Page 15 of 25 37-15 8 - Screw Tightening torque: 3 Nm (27 in lb) Qty. 2 Install with thread- locking fluid AMV185 101 A1 9 - Nut Tightening torque: 5 Nm (44 in lb) Always replace 10 - Washer 11 - Locking lever For ignition lock...
Page 129 Shift mechanism, servicing Page 16 of 25 37-16 14 - Spring For locking pin 15 - Detent plate Assemble selector lever before fitting in selector lever housing Fig. 1 16 - Locking pin With bracket 17 - Socket-head screw Tightening torque: 6 Nm (53 in lb) 18 - Screw Tightening torque: 6...
Page 130 Shift mechanism, servicing Page 17 of 25 37-17 21 - Lever For locking in selector lever position "N" or "P" Adjusting Fig. 2 22 - Bushing 23 - Nut Tightening torque: 10 Nm (7 ft lb) Always replace 24 - Combi-bolt Grease shank http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.1 12/6/2004...
Page 131 Shift mechanism, servicing Page 18 of 25 37-18 Fig. 1 Assembling selector lever before installing Adjust Shiftlock Solenoid -N110- ( Fig. 2 ) and carry out functional check ( Fig. 3 ) before installing selector lever in selector lever housing. - Install set screw and Shiftlock Solenoid -N110- mounting screws with thread-locking fluid AMV 185 101 A1.
Page 132 Shift mechanism, servicing Page 19 of 25 37-19 Fig. 3 Adjusting clearance between push rod and lever Dimension -a- 0.3 mm (0.019 in.) Functional check - Shift selector lever into position "P" and supply Shiftlock Solenoid -N110- with 12 Volts. It must not be possible to shift selector lever into a driving gear.
Page 133 Shift mechanism, servicing Page 20 of 25 37-20 Fig. 4 Mounting indicator lighting connector (Shiftlock Solenoid with single wiring harness) - Push bracket with lug (arrow) on until lug engages. - Seat connector cable into bracket and slide connector onto bracket. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.1 12/6/2004...
Page 134 Shift mechanism, servicing Page 21 of 25 37-21 Locking cable, removing and installing Note: Locking cable must not be kinked. Adjust locking cable after installing page 37- Removing - Remove selector lever handle. - Remove cover with cover strip. - Remove center console. Repair Manual, Body-Exterior, Body-Interior, Repair Group 70.
Page 135 Shift mechanism, servicing Page 22 of 25 37-22 Installing Note: Ensure proper routing of locking cable when installing. - Install locking cable in vehicle. - Mount locking cable eye -1- on locking lever -a-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.1 12/6/2004...
Page 136 Shift mechanism, servicing Page 23 of 25 37-23 - Install locking cable in cable anchor. - Do not tighten screw -a- until after adjusting locking cable. - Mount locking cable clip on locking cable first. - Press locking cable onto ball head. - Press locking cable with clip into support bracket for Ignition/Starter Switch.
Page 137 Shift mechanism, servicing Page 24 of 25 37-24 - Route locking cable along steering column. - Adjust locking cable on cable anchorage of selector lever page 37-25 - Install center console. - Install cover with indicator and selector lever handle. - Attach trim for Ignition/Starter Switch.
Page 138 Shift mechanism, servicing Page 25 of 25 37-25 Locking cable, adjusting Note: Locking cable must only be adjusted in its installation position. - Shift selector lever into "1" position. - Turn ignition key to right ("START" position) and release. - Adjust clearance -a- between lever -1- and locking pin -2- by sliding locking cable casing.
Page 139 Transmission, checking Page 1 of 8 37-26 Transmission, checking Shift points, checking Checking shift points, page 37-27 Stall speed, checking Measuring stall speed, page 37-30 Main pressure, measuring Measuring main pressure, page 37-32 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.2 12/6/2004...
Page 140 Transmission, checking Page 2 of 8 37-27 Shift points, checking Test requirements Carry out On Board Diagnostic program Repair Group 01 - Diagnostic Trouble Code (DTC) Memory interrogated - System in basic setting Check transmission fluid (ATF) level Page 37-43 Check engine settings Repair Manual for the appropriate engine, Fuel Injection &...
Page 141 Transmission, checking Page 3 of 8 37-28 Transmission shifts too early or too late into the next gear When checking the shift points one should note that the Speedometer can deviate from the specified figure within the permissible tolerance. In the tables, the gear shifts are listed according to transmission code letters.
Page 142 Transmission, checking Page 4 of 8 37-29 Shift points (with electronic program switch in TCM) Transmission code letters Gearshifts Kickdown km/h (mph) 1 H - 2 H 61 - 67 ( 38 - 42) 2 H - 3 H 122 - 128 ( 76 - 80) 3 H - 4 M 176 - 182 ( 109 - 113) 4 M - 3 H...
Page 143 Transmission, checking Page 5 of 8 37-30 Stall speed, checking - Connect tachometer (e.g. VAG 1367 engine tester), or read Engine Speed (RPM) using VAG 1551 Scan Tool (ST) to read measured value block. - Hold vehicle stationary with parking brake and foot brake.
Page 144 Transmission, checking Page 6 of 8 37-31 Stall speed chart Transmission code letters Torque converter Stall speed Automatic transmission 096 Code letters QCCR 2350 - 2650 QACA 2750 - 3050 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.2 12/6/2004...
Page 145 Transmission, checking Page 7 of 8 37-32 Main pressure, checking - Before checking the main pressure, check the Diagnostic Trouble Code (DTC) Memory and, if necessary, repair electrical malfunctions. - Check DTC Memory Repair Group 01, On Board Diagnostic Pressure gauge connection for automatic transmission 096 (arrow) - Remove main pressure drilling plug.
Page 146 Transmission, checking Page 8 of 8 37-33 Main pressure specifications: If possible, carry out the main pressure test on a chassis dynamometer (rolling road). Automatic Selector lever positions and test conditions transmission Solenoid Valve connector pulled off 1) Idle Idle Engine Speed (RPM) Engine Speed (RPM) approx.
Page 147 Transmission, removing and installing Page 1 of 9 37-34 Transmission, removing and installing Removing - Obtain radio code on vehicles with coded radio. - Disconnect battery Ground (GND) strap. - Remove battery on vehicles with 6-cylinder engines. - Disconnect speedometer connector at transmission.
Page 148 Transmission, removing and installing Page 2 of 9 37-35 - Clamp-off ATF cooler hoses with 3094 or equivalent and disconnect hoses at ATF cooler. - Disconnect harness connector for Coolant Fan. - Remove upper engine/transmission mounting bolts. - Remove Starter. - Install support bar 10-222 A with legs 10-222 A/1 (6-cyl.
Page 149 Transmission, removing and installing Page 3 of 9 37-36 - Remove vacuum line -a- and connector -b- before installing support bar into eye (arrow) on vehicles with 6-cylinder engines. - Disconnect front mount bracket from engine carrier. - Remove mount bracket. - Remove coolant expansion tank and set aside.
Page 150 Transmission, removing and installing Page 4 of 9 37-37 - Turn steering to right lock. - Raise right axle shaft and secure. - Mark installation position of ball joint bolts on left side control arm and remove bolts. - Vehicles with Plus suspension, remove bolts -A- and loosen bolts -B-.
Page 151 Transmission, removing and installing Page 5 of 9 37-38 - Remove balance weight. - Remove bracket for power steering pressure hose. - Remove torque converter cover plate and remove nuts from torque converter. - Tilt engine and transmission forward with supporting device 3300 A.
Page 152 Transmission, removing and installing Page 6 of 9 37-39 - Move jack VAG 1383 A with transmission support 3282 under transmission and support. - Place securing mount pin on transmission pan and secure to housing (arrow). - Remove lower engine/transmission connecting bolts.
Page 153 Transmission, removing and installing Page 7 of 9 37-40 - Tilt transmission using jack spindle and while lowering ensure cover (wheelhousing side) is guided closely past wheelhousing. - Rotate transmission and lower it carefully. - Secure torque converter to prevent it falling out.
Page 154 Transmission, removing and installing Page 8 of 9 37-41 Installing Installation is carried out in the reverse order. When installing the torque converter, ensure that both drive pins engage in the ATF pump inner wheel recesses. - Before installing, ensure that dowel sleeves for aligning the engine and transmission are correctly located.
Page 155 Transmission, removing and installing Page 9 of 9 37-42 Tightening torques Axle shaft to drive flange 45 Nm (33 ft Torque converter to drive plate 60 Nm (44 ft Transmission to engine bolt M 12 80 Nm (59 ft bolt M 10 60 Nm (44 ft Front mount to mounting 60 Nm (44 ft...
Page 156 ATF level Page 1 of 2 37-43 ATF level ATF level, checking Checking conditions When checking ATF level the transmission must not be in emergency running mode. Vehicle parked on level surface, parking brake applied Selector lever at "P" and engine running at idle speed When cold, the ATF should be visible up to the 20 C marking...
Page 157 ATF level Page 2 of 2 37-44 ATF, topping up CAUTION! Too much ATF will cause transmission malfunctions and must therefore be extracted. This can be done with VAG 1358 A/1 and VAG 1358A probe, or EZ1 fluid evacuator. Only ATF with the designation Dexron may be used.
Page 158 Gear selector elements Page 1 of 2 37-45 Gear selector elements Gear selector elements, position 1 - 2nd and 4th gear brake -B2- 2 - Reverse gear clutch - 3 - 1st to 3rd gear clutch - 4 - 4th gear clutch -K3- 5 - Reverse gear brake - 6 - Free wheel clutch Before starting repairs to the...
Page 159 Gear selector elements Page 2 of 2 37-46 Gear selector elements, function Vehicles with electronic program switch in Transmission Control Module (TCM) Gear B1 B2 K1 K2 K3 F X = clutch, brake or free wheel engaged H = hydraulic M = mechanical http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.5 12/6/2004...
Page 160 Transmission, disassembling and assembling Page 1 of 60 37-47 Transmission, disassembling and assembling ATF cooler and ATF filler tube, removing and installing page 37-48 Planetary gearbox disassembly and assembly, overview page 37-49 Planetary gearbox, disassembling page 37-61 Planetary gearbox, assembling page 37-67 Planetary gearbox adjustments, overview page 37-79...
Page 161 Transmission, disassembling and assembling Page 2 of 60 37-48 ATF cooler and ATF filler tube, removing and installing 1 - Banjo bolt Tightening torque: 35 Nm (26 ft lb) 2 - O-ring Always replace 3 - ATF cooler 4 - O-ring Always replace 5 - Transmission housing 6 - ATF dipstick...
Page 162 Transmission, disassembling and assembling Page 3 of 60 37-49 Planetary gearbox disassembly and assembly, overview Note: Disassembling planetary gearbox page 37-61 Assembling page 37-67 I - ATF pump to support tube, removing and installing page 37- II - Reverse gear clutch -K2- to large sun gear, removing and installing...
Page 163 Transmission, disassembling and assembling Page 4 of 60 37-50 IV - Planet carrier and input gear, removing and installing page 37-59 Note: It is not necessary to remove the input gear (arrow). Removing and installing input gear page 39-8 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6 12/6/2004...
Page 164 Transmission, disassembling and assembling Page 5 of 60 37-51 I - ATF pump to support tube, removing and installing Overview, page 37-49 Note: Disassembling planetary gearbox page 37-61 Assembling page 37-67 1 - Bolt Qty. 7 Tightening torque: 8 Nm (71 in lb) plus an additional -turn (90 )
Page 165 Transmission, disassembling and assembling Page 6 of 60 37-52 5 - Spring cap Qty. 6 Install 3 spring caps after installing first outer plate Install 3 spring caps before installing last outer plate 6 - Spring Qty. 3 7 - Corrugated spring washer 8 - Outer plate -B2- Quantity...
Page 166 Transmission, disassembling and assembling Page 7 of 60 37-53 10 - Outer plate -B2- Always install outer plates that are 2 mm (0.079 in.) thick Quantity from page 00-3 11 - Outer plate -B2- Fit 3 mm (0.118 in.) thick outer plate to supporting tube 12 - Supporting tube -B2- For -B2- plate package...
Page 167 Transmission, disassembling and assembling Page 8 of 60 37-54 II - Reverse gear clutch - K2- to large sun gear, removing and installing Overview, page 37-49 Note: Disassembling planetary gearbox page 37-61 Assembling page 37-67 1 - Reverse gear clutch - Disassembling and assembling page...
Page 168 Transmission, disassembling and assembling Page 9 of 60 37-55 3 - 1st to 3rd gear clutch - K1- with turbine shaft Disassembling and assembling page 38-7 4 - Axial needle bearing washer 5 - Axial needle bearing 6 - Axial needle bearing washer Lugs face toward axial needle bearing...
Page 169 Transmission, disassembling and assembling Page 10 of 60 37-56 8 - Axial needle bearing with washer Axial needle bearing faces toward small drive shaft 9 - Small drive shaft 10 - Needle bearing 11 - Axial needle bearing 12 - Large drive shaft 13 - Axial needle bearing 14 - Axial needle bearing washer...
Page 170 Transmission, disassembling and assembling Page 11 of 60 37-57 III - Free wheel and reverse gear brake -B1-, removing and installing Overview, page 37-49 Note: Disassembling planetary gearbox page 37-61 Assembling page 37-67 1 - Circlip For supporting tube - 2 - Circlip For free wheel 3 - Free wheel with -B1-...
Page 171 Transmission, disassembling and assembling Page 12 of 60 37-58 5 - Pressure plate Install with flat side facing plates Differing plate thickness depending on number of inner plates installed:Thickness with 4 inner plates: 13.5 mm (0.531 in.) Thickness with 5 inner plates: 10.5 mm (0.413 in.) 6 - Inner plate, -B1-...
Page 172 Transmission, disassembling and assembling Page 13 of 60 37-59 IV - Planet carrier and input gear, removing and installing Overview, page 37-49 Note: Disassembling planetary gearbox page 37-61 Assembling page 37-67 1 - Planet carrier Adjusting page 37- 2 - O-ring Always replace Insert in planet carrier 3 - Axial needle bearing...
Page 173 Transmission, disassembling and assembling Page 14 of 60 37-60 7 - Input gear Do not remove to disassemble planetary gearbox Removing and installing input gear or axial needle bearing for planet carrier page 39-8 8 - Planet carrier shim Determining thickness page 37-80 , Planet carrier, adjusting...
Page 174 Transmission, disassembling and assembling Page 15 of 60 37-61 Planetary gearbox, disassembling and assembling Disassembling - Seal ATF cooler connections. - Drain ATF. ATF can be removed using VAG 1358A extraction system with VAG 1358A/1 probe, or EZ1 fluid evacuator. - Remove torque converter.
Page 175 Transmission, disassembling and assembling Page 16 of 60 37-62 - Remove sump. - Remove ATF screen. - Remove valve body. page 38-22 - Remove sealing plugs for -B1-. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6 12/6/2004...
Page 176 Transmission, disassembling and assembling Page 17 of 60 37-63 To remove ATF pump: - Remove ATF pump bolts. - Screw bolts -A- (M8) into tapped holes in ATF pump. - Press ATF pump off transmission by turning bolts -A- evenly. - Take out all clutches with supporting tube, -B2- plates, springs and spring caps together.
Page 177 Transmission, disassembling and assembling Page 18 of 60 37-64 - Insert screwdriver through hole of large drive shaft and large sun gear to loosen and tighten bolt for small drive shaft. - Loosen small drive shaft bolt (arrow). - Remove small drive shaft bolt, washer and shim. Planet carrier axial needle bearing remains in transmission/input gear - Pull out small drive shaft.
Page 178 Transmission, disassembling and assembling Page 19 of 60 37-65 - Pull out large drive shaft (arrow). - Pull out large sun gear (arrow). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6 12/6/2004...
Page 179 Transmission, disassembling and assembling Page 20 of 60 37-66 - Remove supporting tube circlip -a- and free wheel circlip -b-. - Remove free wheel 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.
Page 180 Transmission, disassembling and assembling Page 21 of 60 37-67 Assembling - Install axial needle bearing with washer onto input gear. 1 - Axial needle bearing washer 2 - Axial needle bearing 3 - Axial needle bearing washer - Install smooth side into input gear 4 - Input gear Installed in transmission housing page...
Page 181 Transmission, disassembling and assembling Page 22 of 60 37-68 - Install washer and axial needle bearing into planet carrier. 1 - Axial needle bearing 2 - Axial needle bearing washer 3 - Planet carrier - Install planet carrier into input gear. - Center washer and axial needle bearing in small sun gear.
Page 182 Transmission, disassembling and assembling Page 23 of 60 37-69 - Install inner and outer -B1- plates. - Install pressure plate with flat side facing plates. Thickness of pressure plate varies according to number of plates page 37-58 - Install dished washer with convex side facing toward free wheel.
Page 183 Transmission, disassembling and assembling Page 24 of 60 37-70 - Preload free wheel rollers with 3267 assembly ring and install free wheel. - Install circlip -b- for free wheel and circlip -a- for supporting tube. - Install so that circlip gaps are over free wheel retaining wedge (arrow).
Page 184 Transmission, disassembling and assembling Page 25 of 60 37-71 - Install washer with axial needle bearing in large sun gear. 1 - Axial needle bearing 2 - Washer with shoulder - Install with smooth side facing axial needle bearing 3 - Large sun gear - Install large sun gear with bearing.
Page 185 Transmission, disassembling and assembling Page 26 of 60 37-72 - Install axial needle bearing and needle bearing in large drive shaft. - Install large drive shaft with bearing. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6 12/6/2004...
Page 186 Transmission, disassembling and assembling Page 27 of 60 37-73 - Install small drive shaft. - Install small drive shaft bolt -1- with washer -2- and shim -3-. Tightening torque: 30 Nm (22 ft lb) Note: Install shim -3- onto small drive shaft shoulder (arrow).
Page 187 Transmission, disassembling and assembling Page 28 of 60 37-74 - Install axial needle bearing with washers in 4th gear clutch -K3-. 1 - Axial needle bearing washer 2 - Axial needle bearing 3 - Axial needle bearing washer - Install with smooth side facing -K3-. 4 - 4th gear clutch -K3- Note: Make sure that piston rings seat correctly.
Page 188 Transmission, disassembling and assembling Page 29 of 60 37-75 - Install 4th gear clutch -K3-. - Install shims -a- in -K1-. Notes: Re-measure shim when replacing -K1-, -K2- or ATF pump page 37-94 , Clutch play between - K1- and -K2-, adjusting. 1 or 2 shims can be installed.
Page 189 Transmission, disassembling and assembling Page 30 of 60 37-76 - Install 1st to 3rd gear clutch -K1-. - Install reverse gear clutch -K2-. - Install supporting tube for plate set -B2- (arrow) so that supporting tube groove engages in free wheel wedge.
Page 190 Transmission, disassembling and assembling Page 31 of 60 37-77 - Install -B2- plates as follows: - First install a 3 mm (0.118 in.) thick outer plate. - Install three spring caps in outer plate. - Install compression springs (arrows). - Install all but the last outer plate. - Before installing the last outer plate, install three spring caps onto compression springs.
Page 191 Transmission, disassembling and assembling Page 32 of 60 37-78 - Replace corrugated washer. - Replace ATF pump seal. - Install O-ring on ATF pump. - Install ATF pump. - Tighten bolts evenly, alternating cross-wise. Tightening torque: 8 Nm (71 in lb) plus an additional -turn (90 ) Note:...
Page 192 Transmission, disassembling and assembling Page 33 of 60 37-79 Planetary gearbox adjustments, overview I - Reverse gear brake -B1- A = Shim Determining thickness Reverse gear brake -B1-, adjusting, page 37-87 II - 2nd and 4th gear brake -B2- B = Outer plate Determining thickness page 37-101 , 2nd...
Page 193 Transmission, disassembling and assembling Page 34 of 60 37-80 Planet carrier, adjusting Overview of components to adjust planet carrier - When adjusting planet carrier, install components in transmission housing without shim - 16 -. 1 - Transmission housing With input gear and axial needle bearing Axial needle bearing remains in input gear...
Page 194 Transmission, disassembling and assembling Page 35 of 60 37-81 6 - Planet carrier 7 - Washer 8 - Axial needle bearing 9 - Large sun gear 10 - Washer Insert into large sun gear page 37-67 Planetary gearbox, assembling 11 - Axial needle bearing 12 - Large drive shaft 13 - Axial needle bearing 14 - Needle bearing...
Page 195 Transmission, disassembling and assembling Page 36 of 60 37-82 Determining shim -A- thickness - Install all components to adjust planet carrier in transmission housing. page 37-80 , items - 2 - through - 15 -. - Insert screwdriver through hole of large drive shaft and large sun gear to loosen and tighten bolt for small drive shaft.
Page 196 Transmission, disassembling and assembling Page 37 of 60 37-83 - Install small input shaft bolt -1- with washer -2-, but without shim. Tightening torque: 30 Nm (22 ft lb) - Set up dial indicator so that top of gauge is positioned on center of bolt head with 1 mm preload.
Page 197 Transmission, disassembling and assembling Page 38 of 60 37-84 Table of shims Dial indicator Shim thickness - measurement - mm 1.26 - 1.35 1.36 - 1.45 1.46 - 1.55 1.56 - 1.65 1.66 - 1.75 1.76 - 1.85 1.86 - 1.95 1.96 - 2.05 2.06 - 2.15 2.16 - 2.25...
Page 198 Transmission, disassembling and assembling Page 39 of 60 37-85 Example: Measurement = 2.00 mm: - Insert 1.7 mm shim. - Remove small input shaft bolt. - Install correct shim -3- on small input shaft (arrow). - Tighten small input shaft bolt -1- with washer -2-. Tightening torque: 30 Nm (22 ft lb) - Carry out planet carrier check measurement.
Page 199 Transmission, disassembling and assembling Page 40 of 60 37-86 Planet carrier check measurement - Insert dial indicator in VW 382/7 measuring bar and place the tip on the small input shaft bolt. - Move small input shaft up and down and measure axial play on dial indicator.
Page 200 Transmission, disassembling and assembling Page 41 of 60 37-87 Reverse gear brake -B1-, adjusting Overview of components to adjust reverse gear brake - 1 - Transmission housing 2 - Shim 3 - Outer plate -B1- Quantity from page 00-3 4 - Inner plate -B1- Quantity from page 00-3...
Page 201 Transmission, disassembling and assembling Page 42 of 60 37-88 6 - Dished washer Convex side faces towards free wheel 7 - Free wheel with -B1- piston Note: Before removing or installing free wheel remove valve body and take out sealing plugs page 38-22 8 - Circlip http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6...
Page 202 Transmission, disassembling and assembling Page 43 of 60 37-89 Determining shim -A- thickness Shim thickness is determined by gap -x- and shim is selected from table page 37-92 Gap x = k + A - Shim x - Gap l - Position of piston in free wheel m - Height of plate set including thrust plate K - Constant = 26.8 mm Constant is determined by installation height...
Page 203 Transmission, disassembling and assembling Page 44 of 60 37-90 Calculating free wheel piston position "I": - Press piston in direction of arrows as far as stop. - Place straightedge -A- onto outer race of free wheel. - Measure to inner edge of piston with depth gauge - Example: Measurement 51.8 mm...
Page 204 Transmission, disassembling and assembling Page 45 of 60 37-91 Calculating plate set height "m": - Place straightedge "A" on thrust plate. - Compress set of plates including pressure plate in direction of arrows and measure the thickness of plate set with depth gauge "B". Example: Measurement 73.5 mm...
Page 205 Transmission, disassembling and assembling Page 46 of 60 37-92 Table of shims Gap "x" - mm Shim thickness - mm 2.36 - 2.45 2.46 - 2.55 2.56 - 2.65 2.66 - 2.75 2.76 - 2.85 2.86 - 2.95 2.96 - 3.05 3.06 - 3.15 3.16 - 3.25 3.26 - 3.35...
Page 206 Transmission, disassembling and assembling Page 47 of 60 37-93 Reverse gear brake -B1- check measurement - Install parts up to free wheel and secure with circlip Planetary gearbox, assembling, page 37-67 - Measure clearance between plates with feeler gauge -A-. Specifications: minimum = 1.20 mm maximum = 1.80 mm...
Page 207 Transmission, disassembling and assembling Page 48 of 60 37-94 Clutch play between -K1- and -K2-, adjusting - To adjust clutch play install components without shim - 8 Planetary gearbox, assembling, page 37-67 1 - Transmission housing 2 - Axial needle bearing with washer Axial needle bearing faces towards small...
Page 208 Transmission, disassembling and assembling Page 49 of 60 37-95 5 - Axial needle bearing 6 - Axial needle bearing washer 7 - 1st to 3rd gear clutch - K1- with turbine shaft 8 - Shim Do not install when adjusting clutch play 1 or 2 shims may be installed to achieve correct thickness...
Page 209 Transmission, disassembling and assembling Page 50 of 60 37-96 Determining shim -A- thickness A - Shim 1 - ATF pump 2 - Reverse gear clutch -K2- 3 - 1st to 3rd gear clutch -K1- 4 - 4th gear clutch -K3- - Determine gap "x"...
Page 210 Transmission, disassembling and assembling Page 51 of 60 37-97 Calculating "a": - Place straightedge -A- onto transmission housing. - Press -K1- down in direction of arrow and measure distance into -K1- with depth gauge -B-. Example: Measurement 1 = 88.5 mm - Measure with depth gauge -B- to pump flange on transmission housing.
Page 211 Transmission, disassembling and assembling Page 52 of 60 37-98 Calculating "b": - Place straightedge -B- onto stator support (arrow) and measure with depth gauge -A- to gasket of pump flange. Example: Measurement 70.5 mm - Straightedge height = - 19.5 mm Calculated dimension "b"...
Page 212 Transmission, disassembling and assembling Page 53 of 60 37-99 - Determine shim size according to table. Table of shims Gap "x" - mm Shim thickness - mm - 2.54 2.55 - 3.09 1 + 1 3.10 - 3.49 1.2 + 1.2 3.50 - 3.89 1.4 + 1.4 3.90 - 4.29...
Page 213 Transmission, disassembling and assembling Page 54 of 60 37-100 Check measurement (clutch play) - The clutch play cannot be measured until the ATF pump has been installed. - Attach dial indicator holder to transmission housing and place on turbine shaft with a 1 mm preload.
Page 214 Transmission, disassembling and assembling Page 55 of 60 37-101 2nd and 4th gear brake - B2-, adjusting - Install components to adjust 2nd and 4th gear brake -B2- but without corrugated washer - 11 - and last outer plate - 10 - Planetary gearbox, assembling, page 37-67...
Page 215 Transmission, disassembling and assembling Page 56 of 60 37-102 4 - Outer plate -B2- 3 mm thick 5 - Spring cap Install after installing first outer plate 6 - Outer plate -B2- Always install 2 mm thick outer plates Quantity from page 00-3 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.37.6...
Page 216 Transmission, disassembling and assembling Page 57 of 60 37-103 7 - Inner plate -B2- Quantity from page 00-3 8 - Spring 9 - Spring cap Install before installing last outer plate 10 - Outer plate -B2- Do not install when adjusting -B2- 2 outer plates can be installed.
Page 217 Transmission, disassembling and assembling Page 58 of 60 37-104 Calculating thickness of last outer plate -A- The thickness of the outer plate is determined by gap "x" and is selected from table page 37-106 Gap x = a - b - 3.6 mm A - Outer plate Note: First outer plate (arrow) is always 3 mm thick.
Page 218 Transmission, disassembling and assembling Page 59 of 60 37-105 Calculating "a": - Measure from pump flange/transmission housing to the last inner plate with depth gauge "A". Press inner plate down (in direction of arrow) for this step. Example: Measurement "a" = 30.2 mm Calculating "b": - Place straightedge "B"...
Page 219 Transmission, disassembling and assembling Page 60 of 60 37-106 - Determine thickness of outer plate according to table: Table of plates Gap "x" - mm Plate thickness - mm 4.25 - 4.49 2.75 4.50 - 4.74 3.00 4.75 - 4.99 3.25 5.00 - 5.24 3.50...
Page 220 ATF pump, disassembling and assembling Page 1 of 3 38-1 ATF pump, disassembling and assembling 1 - Piston ring Check that ring is correctly located Fig. 1 Installing Fig. 2 2 - Piston ring Check that ring is correctly located Fig.
Page 221 ATF pump, disassembling and assembling Page 2 of 3 38-2 6 - Bolt Tightening torque: 10 Nm (7 ft lb) plusadditional -turn (45 ) 7 - Stator support 8 - Outer gear Manufacturer's marking faces stator support If outer gear is incorrectly installed, ATF pump may not operate freely in the...
Page 222 ATF pump, disassembling and assembling Page 3 of 3 38-3 Fig. 1 Checking that piston rings are correctly located - Make sure that ends of piston rings are hooked together. Fig. 2 Fitting and hooking ends of piston ring together - Place piston ring in groove.
Page 223 Free wheel with -B1- piston, disassembling and assembling Page 1 of 3 38-4 Free wheel with - B1- piston, disassembling and assembling 1 - Rollers Installing Fig. 1 2 - Springs Installing Fig. 1 3 - Cage Installing Fig. 2 Securing Fig.
Page 224 Free wheel with -B1- piston, disassembling and assembling Page 2 of 3 38-5 Fig. 1 Installing rollers and springs - Install springs so that spring (arrow) engages in cage. Fig. 2 Installing cage with springs and rollers - Install with large lugs (arrow) facing up. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.38.2 12/6/2004...
Page 225 Free wheel with -B1- piston, disassembling and assembling Page 3 of 3 38-6 Fig. 3 Securing cage - Secure cage by turning in direction of arrow as far as stop. Fig. 4 Installed position of piston - Install piston -A- as shown. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.38.2 12/6/2004...
Page 226 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 1 of 6 38-7 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling 1 - Supporting ring 4-piece, unclip from inner plate carrier Installing Fig.
Page 227 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 2 of 6 38-8 6 - Outer plate Quantity page 00-3 Installing Fig. 2 Always 1.5 mm thick 7 - Outer plate Always 2 mm thick Installing Fig.
Page 228 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 3 of 6 38-9 12 - Piston Sealing lips are vulcanized to piston Moisten sealing lips with ATF before installing Turn piston slightly while installing 13 - Piston ring (small diameter) Check that ring is correctly located...
Page 229 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 4 of 6 38-10 Fig. 1 Removing and installing circlip - Press piston cap with intermediate spring ring down far enough for circlip (arrow) to be inserted in groove.
Page 230 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 5 of 6 38-11 Fig. 3 Installing corrugated washer and inner and outer plates in clutch housing - First insert corrugated washer. - Insert 2 mm thick outer plate. - Insert remaining inner and outer plates.
Page 231 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling Page 6 of 6 38-12 Fig. 5 Checking that piston rings are correctly located There are two piston rings installed on the turbine shaft inside the clutch housing. - Make sure that ends of piston rings are hooked together.
Page 232 Reverse gear clutch -K2-, disassembling and assembling Page 1 of 4 38-13 Reverse gear clutch -K2-, disassembling and assembling Note: When performing repairs to the clutch, make sure that the ball valve (arrow) is not damaged. 1 - Circlip Mark after removing and install in same position 2 - Thrust plate...
Page 233 Reverse gear clutch -K2-, disassembling and assembling Page 2 of 4 38-14 4 - Inner plate Quantity page 00-3 5 - Corrugated washer 6 - Circlip Removing and installing Fig. 1 Installation position Fig. 2 7 - Spring supporting plate With springs Installation position Fig.
Page 234 Reverse gear clutch -K2-, disassembling and assembling Page 3 of 4 38-15 8 - Spring supporting ring 9 - Piston Sealing lips are vulcanised to piston Moisten sealing lips with ATF before installing Turn piston slightly while installing 10 - Clutch housing with clutch tube http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.38.4 12/6/2004...
Page 235 Reverse gear clutch -K2-, disassembling and assembling Page 4 of 4 38-16 Fig. 1 Removing and installing circlip Removing - Carefully press down spring supporting plate (do not bend) and spread circlip (arrow). Installing - Install new circlip and carefully press down with spring supporting plate.
Page 236 4th gear clutch -K3- with pump shaft, disassembling and assembling Page 1 of 5 38-17 4th gear clutch -K3- with pump shaft, disassembling and assembling 1 - Circlip Different thicknesses for different clutch assemblies Mark after removing and install in same position 2 - Thrust plate Install with stepped...
Page 237 4th gear clutch -K3- with pump shaft, disassembling and assembling Page 2 of 5 38-18 5 - Pressure plate Install with peened corrugated washer facing piston 6 - Corrugated washer Peened to thrust washer 7 - Circlip Removing and installing Fig.
Page 238 4th gear clutch -K3- with pump shaft, disassembling and assembling Page 3 of 5 38-19 10 - Piston Sealing lips are vulcanized to piston Moisten with ATF before installing Turn piston slightly while installing 11 - Clutch housing with pump shaft Height varies according to number of inner and outer plates...
Page 239 4th gear clutch -K3- with pump shaft, disassembling and assembling Page 4 of 5 38-20 Fig. 1 Removing and installing circlip - Press down carefully on piston cap until circlip (arrow) can be installed. Fig. 2 Checking that piston rings are correctly located There is a piston ring installed on the turbine shaft inside the clutch housing (arrow).
Page 240 4th gear clutch -K3- with pump shaft, disassembling and assembling Page 5 of 5 38-21 Fig. 3 Installing piston rings and hooking ends together - Place piston ring in groove. - To hook ends together press sides of ring in and guide ends over one another.
Page 241 Valve body, removing and installing Page 1 of 9 38-22 Valve body, removing and installing CAUTION! Do not run the engine or tow the vehicle with oil pan removed or when there is no ATF in the transmission. Note: The valve body can also be removed when the transmission is installed.
Page 242 Valve body, removing and installing Page 2 of 9 38-23 3 - Gasket Always replace Press spacer bushings into gasket 4 - Spacer bushing Press into gasket 5 - Bolt Tightening torque: 8 Nm (71 in lb) 6 - ATF screen Press into gasket Installing Fig.
Page 243 Valve body, removing and installing Page 3 of 9 38-24 10 - Bolt Tightening torque: 10 Nm (7 ft lb) 11 - Cable gland Insert with O-ring 12 - O-ring Always replace 13 - Cable connector Attach to starter 14 - Clip 15 - Clip 16 - Nut Tightening torque: 10...
Page 244 Valve body, removing and installing Page 4 of 9 38-25 18 - O-ring Always replace 19 - O-ring Always replace 20 - Operating rod for manual selector valve Adjusting Fig. 3 Install with stepped side facing manual selector valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.38.6 12/6/2004...
Page 245 Valve body, removing and installing Page 5 of 9 38-26 Fig. 1 Installing sealing plug Remove the sealing plug from the housing before removing and installing the free wheel, otherwise the sealing plug and the O-ring will be damaged. Fig. 2 Installing valve body - Route conductor strip as illustrated.
Page 246 Valve body, removing and installing Page 6 of 9 38-27 Fig. 3 Adjusting operating rod for manual selector valve - Move selector shaft to position "P." - Push operating rod with manual selector valve into valve body as far as stop (in direction of arrow) and tighten bolt.
Page 247 Valve body, removing and installing Page 7 of 9 38-28 Fig. 4 Installing ATF screen - Press gasket into ATF screen before installing screen. Fig. 5 Identification of valve body Code letters are stamped on a metal tab. The metal tab must remain on the valve body.
Page 248 Valve body, removing and installing Page 8 of 9 38-29 Valve body conductor strip with transmission fluid temperature sensor, removing and installing If necessary, the conductor strip can be replaced with the transmission installed, without removing the valve body. Removing - Drain Automatic Transmission Fluid (ATF).
Page 249 Valve body, removing and installing Page 9 of 9 38-30 Installing - Route conductor strip as shown; do not kink or twist. - Press gasket into ATF screen before installing screen. - Replace ATF pan gasket. Clip bushing into gasket. Tightening torques Conductor strip to trans.
Page 250 Parking lock, disassembling and assembling Page 1 of 6 38-31 Parking lock, disassembling and assembling Note: The Multi-Function Transmission Range (TR) Switch -F125- and the Vehicle Speed Sensor (VSS) -G68- can be tested in the vehicle by the On Board Diagnostic program page 01-1 , On Board Diagnostic.
Page 251 Parking lock, disassembling and assembling Page 2 of 6 38-32 5 - Supporting plate Installing Fig. 3 6 - Guide plate Install before supporting plate Fig. 3 7 - Bolt Tightening torque: 4 Nm (35 in lb) 8 - Manual selector valve control Adjusting page 38-...
Page 252 Parking lock, disassembling and assembling Page 3 of 6 38-33 14 - Detent segment Insert with selector shaft and engaging lever 15 - Transmission housing 16 - O-ring Always replace 17 - Vehicle Speed Sensor (VSS) -G68- Can be tested in vehicle by On Board Diagnostic program page 01-20...
Page 253 Parking lock, disassembling and assembling Page 4 of 6 38-34 22 - Bracket For Multi-Function Transmission Range (TR) Switch 23 - Bolt Tightening torque: 10 Nm (7 ft lb) 24 - Spring for selector segment 25 - Bolt Tightening torque: 10 Nm (7 ft lb) 26 - Shaft for detent lever Secured by circlip and...
Page 254 Parking lock, disassembling and assembling Page 5 of 6 38-35 Fig. 1 Removing and installing spring pin Driving out - Drive out spring pins (arrows) for engaging lever and detent segment just far enough to remove selector shaft. Note: Spring pin for engaging lever may drop into planetary gearbox.
Page 255 Parking lock, disassembling and assembling Page 6 of 6 38-36 Fig. 3 Installing guide plate and supporting plate Fig. 4 Installing pawl with return spring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.38.7 12/6/2004...
Page 256 Oil in final drive, checking Page 1 of 1 39-1 Oil in final drive, checking Oil level is checked with transmission installed. The difference between the "Min" and "Max" marks is approx. 0.1 liter (3.4 fl. oz.). Excess oil can be drawn off using the VAG 1358A extraction system or EZ1 fluid evacuator.
Page 257 Drive flange oil seal, removing and installing Page 1 of 4 39-2 Drive flange oil seal, removing and installing (Transmission installed) - Disconnect drive shaft from drive flange. When replacing right-hand oil seal: - Remove balance weight. - Lay drive shaft to one side and secure. When replacing left-hand oil seal: - Mark installation position of ball joint/control arm mounting bolts and:...
Page 258 Drive flange oil seal, removing and installing Page 2 of 4 39-3 - Mount installation tool 3109 and remove circlip. - Pull off drive flange with VW 391. - Pull out drive flange oil seal with VW 681. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.2 12/6/2004...
Page 259 Drive flange oil seal, removing and installing Page 3 of 4 39-4 - Pull new oil seal in up to stop with press tool 3319, M10 threaded rod (approx. 80 mm or 3-1/4 in. long) and nut with washer. - Fill space between seal and dust lip with multi- purpose grease.
Page 260 Drive flange oil seal, removing and installing Page 4 of 4 39-5 - Install circlip and seal drive flange with cover. - Install drive shaft. - Reconnect ball joint to control arm. - With transmission installed, check final drive oil level page 39-1 Tightening torque:...
Page 261 Final drive, disassembling and assembling Page 1 of 35 39-6 Final drive, disassembling and assembling Repair overview 1 - Planetary gear Disassembling and assembling page 37-49 2 - Input gear Removing and installing page 39-8 Adjusting page 39- Adjusting final drive (overview) page 39- Note:...
Page 262 Final drive, disassembling and assembling Page 2 of 35 39-7 3 - Drive pinion Removing and installing page 39- Adjusting page 39- Adjusting final drive (overview) page 39- 4 - Differential Removing and installing page 39- Disassembling and assembling page 39-33 Adjusting page 39-...
Page 263 Final drive, disassembling and assembling Page 3 of 35 39-8 Input gear, removing and installing Note: Drive pinion and differential do not need to be removed. 1 - Socket-head fastener Tightening torque: 250 Nm (184 ft lb) Engage parking lock to remove and install Use 22 mm hex wrench...
Page 264 Final drive, disassembling and assembling Page 4 of 35 39-9 4 - Tapered roller bearing inner race Install so that lugs engage in groove of tapered roller bearing inner race - 9 - Fig. Installation position Fig. 4 After measuring thickness of shim, fit onto input gear with AMV 185 101 A1...
Page 265 Final drive, disassembling and assembling Page 5 of 35 39-10 8 - Tapered roller bearing outer race Drive out with drift Drive in with 30-205 and appropriately long drift Install with thread locking fluid AMV 185 101 A1 9 - Tapered roller bearing inner race Pulling off Fig.
Page 266 Final drive, disassembling and assembling Page 6 of 35 39-11 Fig. 1 Pulling off tapered roller bearing inner race - Place press piece on input gear. Fig. 2 Pressing on tapered roller bearing inner race Note: A press piece must be placed below the hub of the input gear to avoid damaging the input gear.
Page 267 Final drive, disassembling and assembling Page 7 of 35 39-12 Fig. 3 Installing tapered roller bearing inner race - Install tapered roller bearing inner race so that the lugs of the inner race engage in the grooves of the opposite inner race (arrow) Fig.
Page 268 Final drive, disassembling and assembling Page 8 of 35 39-13 Fig. 5 Removing input gear - Install socket-head fastener without dished washer, shim and axial needle bearing, just far enough so that gap -a- remains between socket- head fastener and tapered roller bearing inner race.
Page 269 Final drive, disassembling and assembling Page 9 of 35 39-14 Drive pinion, removing and installing Note: To remove the drive pinion, the selector shaft must be removed after taking out the parking lock page 38-31 , Parking lock, disassembling and assembling. 1 - Drive pinion Number of teeth from page 00-3...
Page 270 Final drive, disassembling and assembling Page 10 of 35 39-15 4 - Hex nut Tightening torque: 250 Nm (184 ft lb) Engage parking lock to remove or install Secure with drift 5 - Output gear Number of teeth from page 00-3 Technical data Pulling off Fig.
Page 271 Final drive, disassembling and assembling Page 11 of 35 39-16 10 - Shim Determining thickness page 39-44 , Drive pinion, adjusting 11 - Parking lock gear Rounded side faces teeth of drive pinion 12 - Bearing support ring Tightening torque: 200 Nm (148 ft lb) Remove screw - 3 - before removing or...
Page 272 Final drive, disassembling and assembling Page 12 of 35 39-17 13 - O-ring Always replace Place onto bearing support ring - 12 - 14 - Oil seal for drive pinion Remove with screwdriver Installation position Fig. 6 Driving in Fig. 7 15 - Tapered roller bearing outer race Driving in...
Page 273 Final drive, disassembling and assembling Page 13 of 35 39-18 Fig. 1 Pulling off output gear A - Kukko 20-10 and Matra V 172 pulling hooks Fig. 2 Pulling off tapered roller bearing inner race - Place press piece onto collar of output gear. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 274 Final drive, disassembling and assembling Page 14 of 35 39-19 Fig. 3 Pressing on tapered roller bearing inner race Fig. 4 Pressing in tapered roller bearing outer race http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 275 Final drive, disassembling and assembling Page 15 of 35 39-20 Fig. 5 Removing and installing bearing supporting ring A - Torque wrench - Tighten bearing supporting ring. Tightening torque: 200 Nm (148 ft lb) - Secure with locking screw. Install screw with thread sealing compound AKD45600001.
Page 276 Final drive, disassembling and assembling Page 16 of 35 39-21 Fig. 7 Driving in drive pinion oil seal - Install oil seal so that sealing lip faces special tool 30-204. Fig. 8 Removing drive pinion http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 277 Final drive, disassembling and assembling Page 17 of 35 39-22 Fig. 9 Driving in tapered roller bearing outer race - Install drive pinion with tapered roller bearing inner race, then drive in outer race. Fig. 10 Pressing on tapered roller bearing inner race http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 278 Final drive, disassembling and assembling Page 18 of 35 39-23 Differential, removing and installing Note: If tapered roller bearings are to be re-used, mark the adjusting ring Fig. 2 The drive pinion does not need to be removed for removing and installing the differential.
Page 279 Final drive, disassembling and assembling Page 19 of 35 39-24 5 - Adjusting ring Removing Fig. 3 If used bearings are re-installed, mark installation position and line up on marking again when installing Fig. 2 If new bearings are installed, pay attention to setting instructions page 39-51 Differential, adjusting...
Page 280 Final drive, disassembling and assembling Page 20 of 35 39-25 10 - Drive flange Install with tapered ring, thrust washer and compression spring Remove before taking out inner circlip on bevel gear Removing and installing Fig. 4 11 - Dished washer 12 - Circlip 13 - Cover 14 - Locking element...
Page 281 Final drive, disassembling and assembling Page 21 of 35 39-26 19 - Drive flange Install with tapered ring, thrust washer and compression spring Remove before taking out inner circlip on bevel gear Removing and installing Fig. 4 20 - Compression spring 21 - Thrust washer Place over compression spring...
Page 282 Final drive, disassembling and assembling Page 22 of 35 39-27 24 - Bearing body Tightening torque: 150 Nm (111 ft lb) When installing new bearing, pay attention to setting instructions page 39-51 Differential, adjusting Remove with tool 3155 Installing Fig. 5 25 - O-ring Always replace 26 - Output shaft/drive...
Page 283 Final drive, disassembling and assembling Page 23 of 35 39-28 30 - Circlip First remove drive flange before removing circlip Removing and installing Fig. 6 31 - Circlip First remove drive flange before removing circlip Removing and installing Fig. 6 32 - Seal Always replace 33 - Cover...
Page 284 Final drive, disassembling and assembling Page 24 of 35 39-29 Fig. 1 Driving in drive flange oil seal up to stop Fig. 2 Marking adjusting ring - If used bearings are re-installed, mark installation position (arrow) and use marking to position adjusting ring when installing.
Page 285 Final drive, disassembling and assembling Page 25 of 35 39-30 Fig. 3 Removing adjusting ring Fig. 4 Removing and installing drive flange Note: Drive flange can also be removed with VW 391. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 286 Final drive, disassembling and assembling Page 26 of 35 39-31 Fig. 5 Installing differential - Screw in bearing body as far as stop, then tighten. Tightening torque: 150 Nm (111 ft lb) Fig. 6 Installing circlip - Remove circlip (arrow) with two screwdrivers. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 287 Final drive, disassembling and assembling Page 27 of 35 39-32 Fig. 7 Speedometer drive - With transmission installed, check gear oil in final drive page 39-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 288 Final drive, disassembling and assembling Page 28 of 35 39-33 Differential, disassembling and assembling Note: Heat tapered roller bearing inner race to 100 C (212 F) before pressing on. Heat adjusting ring for tapered roller bearing to 100 C (212 F) before pressing in tapered roller bearing outer race.
Page 289 Final drive, disassembling and assembling Page 29 of 35 39-34 3 - Tapered roller bearing inner race Pulling off Fig. 1 Pressing on Fig. 2 4 - Tapered roller bearing outer race Remove and install only when adjusting ring heated Drive out with drift Pressing in Fig.
Page 290 Final drive, disassembling and assembling Page 30 of 35 39-35 7 - O-ring Always replace 8 - Adjusting ring for tapered roller bearing Removing and installing page 39- , Differential, removing and installing 9 - Output shaft/drive flange Removing and installing page 39- , Differential,...
Page 291 Final drive, disassembling and assembling Page 31 of 35 39-36 12 - Speedometer drive bushing Drive off together with speedometer drive gear - 13 - Drive on with drift 13 - Speedometer drive gear Drive out with drift Fit on together with driver bushing -item 12 14 - One-piece thrust washer...
Page 292 Final drive, disassembling and assembling Page 32 of 35 39-37 18 - Shaft for bevel gears Drive out with drift When driving in, do not damage one-piece thrust washer 19 - Spring pin For securing shaft for bevel gears Removing and installing spring pin with circumferential groove...
Page 293 Final drive, disassembling and assembling Page 33 of 35 39-38 Fig. 1 Pulling off tapered roller bearing inner race - Place press tool 30-555 on differential housing. Fig. 2 Pressing on tapered roller bearing inner race http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 294 Final drive, disassembling and assembling Page 34 of 35 39-39 Fig. 3 Installing differential bevel gears - Install one-piece thrust washer with gear oil. - Install small bevel gears, drive in shaft and secure with spring pin. - Install large bevel gears offset 180 and swivel in (in direction of arrow).
Page 295 Final drive, disassembling and assembling Page 35 of 35 39-40 Fig. 5 Removing and installing spring pin with circumferential groove Length of spring pin: 28.5 mm (1.122 in.) Removing - Pull out spring pin with side-cutting pliers. Installing - Drive in spring pin as far as stop. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.39.3 12/6/2004...
Page 296 Final drive, adjusting Page 1 of 12 39-41 Final drive, adjusting Adjustment overview 1 - Input gear Adjusting page 39- 2 - Drive pinion Adjusting page 39- 3 - Differential Adjusting page 39- 4 - Shim for input gear Determine thickness from table page 39- Determine Part No.
Page 297 Final drive, adjusting Page 2 of 12 39-42 6 - Shim for differential 7 - Tapered roller bearings for input gear Always replace together Measure friction torque via pinion shaft. Friction torque of new tapered roller bearings must be 180-220 Ncm (16-20 in lb) greater than friction torque of pinion shaft...
Page 298 Final drive, adjusting Page 3 of 12 39-43 Adjustments to be completed after replacing individual components When working on transmission the following components only require adjustment if individual components have been replaced that directly affect the final drive adjustment. To eliminate unnecessary adjustments observe following table: To adjust: Components being replaced:...
Page 299 Final drive, adjusting Page 4 of 12 39-44 Drive pinion, adjusting Conditions: Supporting ring for drive pinion bearing installed and secured. Parking lock mechanism and parking lock gear installed. Adjusting: - Place two shims (arrow), each 1.5 mm thick, onto the drive pinion.
Page 300 Final drive, adjusting Page 5 of 12 39-45 Determining shim thickness The specified bearing preload is achieved if the reading (example: 0.93 mm), the specified bearing preload (0.12 mm) and the amount allowed for compression (0.10mm) are deducted from the 2 x 1.5 mm thick shims. Example: Shims installed (2 x 1.5 mm) 3.00 mm...
Page 301 Final drive, adjusting Page 6 of 12 39-46 Table of shims for drive pinion and input gear Measured Shim Measured Shim Measured Shim thickness - thickness - mm thickness - thickness - thickness - thickness - 0.975 - 0.999 1.000 1.550 - 1.574 1.575 2.125 - 2.149...
Page 302 Final drive, adjusting Page 7 of 12 39-47 Checking friction torque A - Torque gauge, commercially available, 0-600 Ncm (0-50 in lb) B - Wrench socket (41 mm AF) - Oil bearing beforehand with gear oil. Friction torque of new tapered roller bearings must be 80-120 Ncm (7-11 in lb).
Page 303 Final drive, adjusting Page 8 of 12 39-48 Input gear, adjusting - Tighten socket-head fastener to 100 Nm (74 ft lb) without dished washer and without shim. The parking lock must be engaged. A - Torque wrench B - 22 mm socket - Remove socket-head fastener.
Page 304 Final drive, adjusting Page 9 of 12 39-49 Determining shim thickness The correct shim thickness determined by deducting the specified bearing preload of 0.18 mm from the figure of 2.50 mm (example) obtained from the measurement. Example: Dished washer thickness (1.50 2.50 mm + dial indicator measurement (example: 1.00 mm)
Page 305: Input Gear
Final drive, adjusting Page 10 of 12 39-50 Checking friction torque A - Torque gauge, commercially available 0-600 Ncm (0-50 in lb) B - Socket (41 mm AF) - Moisten bearings beforehand with ATF. The friction torque of new tapered roller bearings must be 180-220 Ncm (16-20 in lb) greater than the friction torque at the drive pinion.
Page 306: Adjusting
Final drive, adjusting Page 11 of 12 39-51 Differential, adjusting - Tighten bearing body with tool 3155 as far as the stop and secure. Tightening torque: 150 Nm (111 ft lb) - Tighten adjusting ring and mark its position. Tightening torque: 50 Nm (37 ft lb) Note: Do not rotate the differential while making this measurement, as the bearings will otherwise settle...
Page 307: Differential
Final drive, adjusting Page 12 of 12 39-52 Checking friction torque A - Torque gauge, commercially available 0-600 Ncm (0-50 in lb) B - Socket (41 mm AF) - Oil bearing beforehand with gear oil. Example: Friction torque Drive pinion (measurement) 300 Ncm1) Differential (average) 70 Ncm...

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Volkswagen Passat 1995 Official Factory Repair Manual

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