Transmission, Disassembling And Assembling – Planetary
Contents
1. 9 Bearing cap 39 16 10 Shim Determining thickness page 39 45 Drive pinion adjusting 11 Parking lock gear Rounded side faces teeth of drive 12 Bearing support ring Tightening torque 200 Nm 148 ft Ib Remove screw 3 before removing or installing bearing support ring Removing or installing Fig 5 Bearing support ring cannot be unscrewed until the selector shaft has been removed page 38 45 Parking lock disassembling and assembling Install bearing supporting ring carefully Sealing lip and spring must not be damaged Supporting ring with seal Fig 6 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 Fig 9 16 Tapered roller bearing inner race Drive off with drift Pressing on Fig 10 39 18 lt Fig 1 Pulling off output gear A Kukko 20 10 and Matra V 172 pulling hooks lt Fig 2 Pulling off tapered roller bearing inner race Place press piece onto collar of output gear 39 19 lt Fig 3 Pressing on tapered roller bearing inner race lt Fig 4 Pressing in tapered roller bearing outer race 39 20 lt Fig 5 Removing and installing bearing supporting ring A Torque wrench Tighten bearing supporting ring Tightening torque 200 Nm 1482. With input gear and axial needle bearing Axial needle bearing remains in input gear Damaged axial needle bearing page39 8 Input gear removing and installing 2 Axial needle bearing washer Insert smooth side in input gear 3 Axial needle bearing 4 Axial needle bearing washer 37 91 5 O ring Insert into planet carrier page 37 76 Planetary gearbox assembling 6 Planet carrier 7 Small sun gear Cannot be removed from planet carrier in transmissions from 01 93 page 00 5 8 Washer 9 Axial needle bearing 10 Large sun gear 11 Washer Insert into large sun gear page 37 76 Planetary gearbox assembling 12 Axial needle bearing 13 Large drive shaft 19 37 92 14 Axial needle bearing 15 Needle bearing 16 Small drive shaft 17 Shim Do not install in planet carrier when adjusting 18 Washer 19 Small drive shaft bolt Tightening torque 30 Nm 22 ft Ib 19 37 93 lt Determining shim A thickness Install all components to adjust planet carrier in transmission housing page 37 90 items 2 through 16 lt Insert screwdriver through hole of large drive shaft and large sun gear to loosen and tighten bolt for small drive shaft 37 94 lt Install small input shaft bolt 1 with washer 2 but without shim Tightening torque 30 Nm 22 ft Ib lt Set up dial indicator so that top of gauge is positio
3. 9 Small drive shaft 10 Needle bearing 11 Axial needle bearing 37 63 12 Large drive shaft Modified K1 clutch from 01 93 13 Axial needle bearing 14 Axial needle bearing washer With shoulder 15 Large sun gear Transmissions up to 12 92 27 teeth page 00 3 Transmissions from 01 93 24 teeth page 00 5 16 Axial needle bearing Transmissions up to 12 92 outer diameter 41 mm 1 61 in page 00 3 Transmissions from 01 93 outer diameter 39 1 mm 1 54 in page 00 5 17 Axial needle bearing washer 18 Small sun gear Cannot be removed from planet carrier in transmissions from 01 93 page 00 5 37 64 lll Free wheel and reverse gear brake B1 removing and installing Overview page 37 55 Note Disassembling planetary gearbox page 37 70 Assembling gt page 37 76 1 Circlip For supporting tube B2 2 Circlip For free wheel 3 Free wheel with B1 piston Before removing free wheel remove valve body and sealing plugs page 38 36 Disassembling and assembling page 38 4 4 Dished spring Install with convex part facing free wheel 37 65 5 Pressure plate Install with flat side facing plates Differing plate thickness depending on number of inner plates installed Up to transmission build date 16 08 2 With 4 inner plates 7 5 mm 0 295 in an additional 3 7 mm 0 146 in shim 8 is installed With 5 inne
4. A final drive overview page 39 Note Repairs on the input gear can be carried out only after the component parts of the planetary gear have been removed 3 Drive pinion Removing and installing page 39 14 Adjusting page 39 45 ooo final drive overview gt page 39 4 Differential Removing and installing page 39 23 Disassembling and assembling page 39 34 Adjusting page 39 52 Adjusting final drive overview page 39 42 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 Ib Engage parking lock to remove and install Use 22 mm hex wrench Before installing socket head fastener insert axial needle bearing 7 2 Dished washer Curved side faces socket head fastener 3 Shim Determining thickness page 39 49 Input gear adjusting 39 9 4 Tapered roller bearing inner race Install so that lugs engage in groove of tapered roller bearing inner race 9 Fig 3 Installation position Fig 4 After measuring thickness of shim fit onto input gear with AMV 185 101 A1 thread locking fluid 5 Tapered roller bearing outer race Drive out with drift Drive in with tool 30 205 Install with AMV 185 101 A1 locking fluid 6 Transmission housing 7 Axial needle bearing Install with flat side facing input gear Insert into
5. Bearing body 23 Tightening torque 150 Nm 111 ft Ib 28 29 33 When installing new bearing pay attention to setting instructions page 39 52 Differential adjusting Remove with tool 3155 Installing Fig 5 25 O ring Always replace 39 28 26 Output shaft drive flange 16 Install thread facing drive flange 17 Before removing take out differential 18 19 20 21 22 23 Before removing differential take out bearing body adjusting ring and output 28 29 33 shafts 28 Screw Tightening torque 12 Nm 9 ft Ib First adjust differential before installing 27 Differential Disassembling and assembling page 39 34 29 Locking element 30 Circlip First remove drive flange before removing circlip Removing and installing Fig 6 39 29 31 Circlip 16 First remove drive flange before removing 47 circlip 18 Removing and installing Fig 6 19 32 Seal 20 Always replace 21 33 Cover 22 23 28 29 33 34 Screw Tightening torque 28 Nm 21 ft Ib Install with thread locking fluid AMV 185 101 A1 For differential Note After adjusting tapered roller bearings secure bearing body and adjusting ring 39 30 lt Fig 1 Driving in drive flange oil seal up to stop lt Fig 2 Marking adjusting ring If used bearings are re installed mark installation position arrow and use marking to position adjusting ring when installing
6. 104 Gap x k 5 m A Shim x Gap 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 in transmission housing and is not adjustable 37 102 Calculating 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 B Example Measurement 51 8mm Straightedge height 48 2mm Calculated dimension I 3 6 mm lt 37 103 Calculating 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 5mm Straightedge height 48 2mm Calculated dimension m 25 3mm 26 8 25 3 3 3mm 26 3 25 3 3 3mm Determine size of shims according to table 37 104 Table of shims Gap x mm_ Shim thickness mm 2 36 2 45 1 0 2 46 2 55 1 1 2 56 2 65 1 2 2 66 2 75 1 3 2 76 2 85 1 4 2 86 2 95 1 5 2 96 3 05 1 6 3 06 3 15 1 7 3 16 3 25 1 8 3 26 3 35 1 9 3 36 3 45 1 0 1 0 3 46 3 55 1 0 1 1 3 56 3 65 1 1 1 1 3 66 3 75 1 1 1 2 3 76 3 85 1 2 1 2 3 86 3 95 1 2 1 3 3 96 4 05 1 3 1 3 4 06 4 15 1 3 1 4 4 16 4 25 1 4 1 4 Determine thickness of shims according to
7. ft Ib Secure with locking screw Install screw with thread sealing compound AKD45600001 lt Fig 6 Bearing supporting ring with seal for drive pinion Installation position of seal Open side arrow faces toward tapered roller bearing outer race 39 21 lt Fig 7 Driving in drive pinion oil seal Install oil seal so that sealing lip faces special tool 30 204 lt Fig 8 Removing drive pinion V39 1803 39 22 lt Fig 9 Driving in tapered roller bearing outer race Install drive pinion with tapered roller bearing inner race then drive in outer race lt Fig 10 Pressing on tapered roller bearing inner race 16 17 18 19 20 21 22 23 28 29 33 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 1 Transmission housing 2 Speedometer drive With marking for oil level indication Fig 7 3 Output shaft drive flange Install thread facing drive flange Remove before taking out differential First adjust differential before installing 39 24 4 O ring 16 Always replace 17 5 Adjusting ring 18 19 If used bearings are re installed mark 20 installation position and line up on marking 21 again when installing Fig 2 Removing Fig 3 22 If new bearings are install
8. input gear before installing socket head fastener 1 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 1 Pressing on Fig 2 Installation position Fig 4 Install with AMV 185 101 A1 locking fluid 10 Input gear With impulse wheel for Vehicle Speed Sensor VSS G68 Number of teeth page 00 3 Technical data Adjusting page 39 49 If signs of damage exist always replace input gear and output gear together Removing Fig 5 Note If input gear is replaced adjust planet carrier page 37 8 39 11 lt Fig 1 Pulling off tapered roller bearing inner race Place press piece on input gear lt 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 39 12 lt 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 lt Fig 4 Installation position of tapered roller bearing inner race Lug arrow must engage in groove of the opposite inner race Note Tapered roller bearings without lugs can also be installed 39 13 lt Fig 5 Removing inp
9. measurement page 37 97 37 83 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 3rd and 4th gear clutch K3 Note Make sure that piston rings seat correctly 37 84 Install axial needle bearing with washer on 4th gear clutch K3 1 Axial needle bearing with washer Moisten axial needle bearing washer with ATF so that bearing 1 while installing sticks to K3 Install bearing washer on K3 2 3rd and 4th gear clutch K3 Install 3rd and 4th gear clutch K3 Transmissions from 01 93 K3 clutch operates only 4th gear page 00 5 lt 37 85 Install shims a in K1 Notes Re measure shim when replacing K1 K2 or ATF pump page 37 106 Clutch play between K1 and K2 adjusting 1 or 2 shims can be installed Install 1st to 3rd gear clutch K1 37 86 Install reverse gear clutch K2 lt Install supporting tube for plate set B2 arrow so that supporting tube groove engages in free wheel wedge 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 37 87 Before installing the last outer plate install three spring ca
10. table and determine Part No from parts catalog microfiche After determining shim for B1 carry out check measurement page 37 105 lt 37 105 Reverse gear brake B1 check measurement Install parts up to free wheel and secure with circlip Planetary gearbox assembling page 37 76 Measure clearance between plates with feeler gauge A Specifications minimum 1 20 mm maximum 1 80 mm 37 106 Clutch play between K1 and K2 adjusting To adjust clutch play install components without shim 8 Planetary gearbox assembling age 37 76 1 Transmission housing 2 Axial needle bearing with washer Axial needle bearing faces towards small input shaft Washer faces toward K3 3 3rd and 4th gear clutch K3 with pump shaft On transmissions from 01 93 the K3 clutch operates only 4th gear page 00 5 4 Axial needle bearing washer Lugs face toward axial needle bearing 37 107 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 9 Reverse gear clutch K2 37 108 lt 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 Note On transmissions from 01 93 clutch K
11. 3 operates only 4th gear page 00 5 Calculating thickness of shim Determine gap x and calculate shim thickness Gapx a b 37 109 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 Example Measurement 2 34 3 mm Measurement 1 88 5 mm Measurement 2 34 3 mm Calculated dimension a 54 2 mm Dimension measured from pump flange transmission housing into K1 37 110 Calculating b Place straightedge B onto stator support arrow and measure with depth gauge A to gasket of pump flange Example 70 5mm 19 5mm Measurement Straightedge height Calculated dimension b 51 0mm Gapx a b 54 2 51 0 3 2mm Determine shim size according to table Table of shims Gap x mm 2 54 2 55 3 09 3 10 3 49 3 50 3 89 3 90 4 29 4 30 4 69 4 70 5 04 5 05 5 25 37 111 Shim thickness mm 1 4 1 1 1 2 1 2 1 4 1 4 1 6 1 6 1 8 1 8 1 2 1 2 1 6 1 2 1 2 1 8 Determine thickness of shims according to table and determine Part No from parts catalog microfiche Carry out clutch play check measurement after installing ATF pump 37 112 Check measurement clutch play The
12. 37 53 Transmission disassembling and assembling ATF cooler and ATF filler tube removing and installing page 37 54 Planetary gearbox disassembly and assembly overview page 37 55 Planetary gearbox disassembling page 37 70 Planetary gearbox assembling page 37 76 Planetary gearbox adjustments overview page 37 89 Valve body removing and installing page 38 36 37 54 ATF cooler and ATF filler tube removing and installing 1 Banjo bolt Tightening torque 35 Nm 26 ft Ib 2 O ring Always replace 3 ATF cooler 4 O ring Always replace 5 Transmission housing 6 ATF dipstick Checking ATF level page 37 47 7 ATF filler tube 8 Bolt 9 O ring Always replace RC f gt A s Te o req Q Q O Q Q Q 6 gt N37 0029 37 55 Planetary gearbox disassembly and assembly overview Note Disassembling planetary gearbox page 37 70 Assembling page 37 76 ATF pump to support tube removing and installing page 37 57 ll Reverse gear clutch K2 to large sun gear removing and installing page 37 61 Note The small sun wheel arrow 1 cannot be removed from the planet carrier in transmissions from 01 93 page 00 5 37 56 lll Free wheel and reverse gear brake B1 removing and installing page 37 64 Note j in i 3 s c To remove and install free wheel first remove valve body together with p
13. 39 31 lt Fig 3 Removing adjusting ring lt Fig 4 Removing and installing drive flange Note Drive flange can also be removed with VW 391 39 32 A Fig 5 Installing differential Screw in bearing body as far as stop then tighten Tightening torque 150 Nm 111 ft Ib lt Fig 6 Installing circlip Remove circlip arrow with two screwdrivers 39 33 lt Fig 7 Speedometer drive With transmission installed check gear oil in final drive page 39 1 39 34 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 1 Differential housing with riveted gear for final drive Final drive gear is riveted onto differential housing and then machined If differential or final drive gear is damaged replace differential housing along with riveted final drive gear Number of teeth on final drive gear from page 00 3 Technical data 39 35 2 Output shaft drive flange Removing and installing page 39 23 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 4 5 Bearing body for tapered roller bearing Remo
14. ck that ring is correctly located Fig 1 Installing Fig 2 2 Piston ring Check that ring is correctly located Fig 1 Installing Fig 2 3 Piston ring Check that ring is correctly located Fig 1 Installing Fig 2 4 Thrust washer 5 Piston Sealing lips are vulcanized to piston Moisten sealing lips with ATF before installing Turn piston slightly while installing 38 2 6 Bolt Tightening torque 10 Nm 7 ft Ib plusadditional 1 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 installed position 9 Inner gear Larger groove faces stator support 10 Housing for ATF pump 11 O ring Always replace 12 Torque converter oil seal Removing and installing page 32 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 To hook ends together press sides of ring in and guide ends over one another Do not twist piston ring out of groove on one side Final drive disassembling and assembling Repair overview 1 Planetary gear Disassembling and assembling page 37 55 2 Input gear Removing and installing page 39 8 Adjusting page 39 49
15. 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 lt Move turbine shaft up and down and read axial play on dial indicator gauge Specifications minimum 0 5 mm 0 020 in maximum 1 2 mm 0 047 in 37 113 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 76 1 Transmission housing 2 Circlip For supporting tube 3 Supporting tube B2 Length of B2 4 inner plates 72 3 mm 2 847 in 5 inner plates 68 6 mm 2 701 in 6 inner plates 64 9 mm 2 555 in Quantity inner plates B2 from page 00 3 Insert so that notch locates on free wheel wedge 37 114 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 7 Inner plate B2 Quantity from page 00 3 8 Spring 9 Spring cap Install before installing last outer plate 37 115 10 Outer plate B2 Do not install when adjusting B2 2 outer plates can be installed 11 Corrugated washer Do not install when adjusting B2 37 116 lt Calculating thickness of last
16. e drive shaft arrow Pull out large sun gear arrow lt 37 75 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 Note Itis not necessary to remove input gear to disassemble the planetary gearbox Removing and installing input gear page 39 8 Assembling planetary gearbox page 37 76 lt 37 76 Planetary gearbox 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 4 Input gear Installed in transmission housing page 37 55 Install O ring in planet carrier Note After replacing planet carrier adjust page 37 90 lt 37 77 Install washer and axial needle bearing into planet carrier 1 Axial needle bearing Transmissions up to 12 92 outer diameter 41 0 mm 1 61 in page 00 3 Transmissions from 01 93 outer diameter 39 1 mm 1 54 in page 00 5 2 Axial needle bearing washer 3 Small sun gear Cannot be removed for transmissions from 01 93 page 00 5 4 Planet carrier Install planet carrier into input gear Center washer and axial needle bearing in small sun gear 37 78 Install i
17. ed pay attention 23 to setting instructions page 39 52 Differential adjustin 28 29 33 pone 6 Oil seal for drive flange Before installing pack space between sealing lips with multi purpose grease Can be replaced with transmission installed page 39 2 Remove with VW 681 Driving in Fig 1 39 25 7 Tapered ring 16 Shoulder faces thrust washer 17 8 Thrust washer 18 19 20 21 10 Drive flange Place over compression spring 9 Compression spring 22 Install with tapered ring thrust washer and 23 compression spring 28 29 33 Remove before taking out inner circlip on bevel gear Removing and installing Fig 4 11 Dished washer 12 Circlip 13 Cover 14 Locking element 15 Screw Tightening torque 12 Nm 9 ft Ib 39 26 16 Cover 16 17 Circlip 17 18 Dished washer 18 19 Drive flange 19 Install with tapered ring thrust washer and 20 compression spring 21 Remove before taking out inner circlip on 22 bevel gear 23 Removing and installing gt Fig 4 28 29 33 20 Compression spring 21 Thrust washer Place over compression spring 22 Tapered ring Shoulder faces thrust washer 39 27 23 Oil seal for drive flange 16 Before installing pack space between 47 sealing lips with multi purpose grease 18 Can be replaced with transmission installed 19 page 39 2 20 Remove with VW 681 21 Driving in Fig 1 22 24
18. ed roller bearing inner race Place press tool 30 555 on differential housing lt Fig 2 Pressing on tapered roller bearing inner race ums 39 40 lt 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 lt Fig 4 Pressing in tapered roller bearing outer race With adjusting ring or bearing body heated install outer race and press home as far as stop V39 1657 39 41 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
19. installing planet carrier Planetary gearbox assembling page 37 76 37 98 Reverse gear brake B1 adjusting Overview of components to adjust reverse gear brake B1 1 Transmission housing 2 Shim Up to transmission build date 16 08 2 additional 3 7 mm 0 146 in shim for B1 with 4 inner plates item 5 3 Outer plate B1 Quantity from page 00 3 4 Inner plate B1 Quantity from page 00 3 37 99 5 Pressure plate B1 Install with flat side facing plates Differing thicknesses depending on number of inner plates installed Up to transmission build date 16 08 2 With 4 inner plates 7 5 mm 0 295 in an additional 3 7 mm 0 146 in shim 8 is installed With 5 inner plates 7 5 mm 0 295 in From transmission build date 17 08 2 With 4 inner plates 11 1 mm 0 437 in With 5 inner plates 7 5 mm 0 295 in Transmissions from 01 93 With 4 inner plates 13 5 mm 0 5371 in With 5 inner plates 10 5 mm 0 413 in Quantity of B1 inner plates from page 00 3 37 100 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 36 8 Circlip N37 0043 37 101 Determining shim A thickness Shim thickness is determined by gap x and shim is selected from table page 37
20. lugs page 38 36 IV Planet carrier and input gear removing and installing page 37 67 gt Note Itis not necessary to remove the input gear arrow Removing and installing input gear page 39 8 req 000000000000 00 t N37 0029 37 57 ATF pump to support tube removing and installing Overview page 37 55 Note Disassembling planetary gearbox page 37 70 Assembling page 37 76 1 Bolt Qty 7 Tightening torque 8 Nm 71 in lb plus an additional 1 4 turn 90 The additional turn 90 may be done in several stages 2 ATF pump with B2 piston Disassembling and assembling page 38 ni 3 O ring Always replace Place on ATF pump 37 58 4 Gasket Always replace 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 from page 00 3 Determining thickness of outer plate page 37 113 2nd and 4th gear brake B2 adjusting 37 59 9 Inner plate B2 Quantity from page 00 3 Before installing place in in ATF for 15 minutes 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
21. m Determining thickness page 37 90 Planet carrier adjusting 9 Washer 10 Bolt Tightening torque 30 Nm 22 ft Ib For small input shaft 37 69 11 Spacer bush Qty 7 Clip into gasket 12 Gasket Always replace 13 Cover 14 Bolt Tightening torque 8 Nm 71 in Ib 37 70 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 Secure transmission to assembly support with bolts 1 and 2 Remove transmission housing cover with gasket arrow 37 71 Remove sump Remove ATF screen lt Remove valve body page 38 36 lt Remove sealing plugs for B1 37 72 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 37 73 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 37 74 Pull out larg
22. ned on center of bolt head with 1 mm preload Zero dial gauge Move small input shaft up and take measurement Example measurement 2 00 mm Specify thickness of shim according to table and determine Part No from parts catalog microfiche 37 95 Table of shims Dial indicator Shim thickness measurement mm mm 1 26 1 35 1 0 1 36 1 45 1 1 1 46 1 55 1 2 1 56 1 65 1 3 1 66 1 75 1 4 1 76 1 85 1 5 1 86 1 95 1 6 1 96 2 05 1 7 2 06 2 15 1 8 2 16 2 25 1 9 2 26 2 35 2 0 2 36 2 45 2 1 2 46 2 55 2 2 2 56 2 65 2 3 2 66 2 75 2 4 2 76 2 85 2 86 2 95 2 96 3 05 3 06 3 15 3 16 3 25 2 5 2 6 2 1 2 8 2 9 37 96 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 Ib Carry out planet carrier check measurement page 37 97 37 97 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 Specifications min 0 23 mm 0 0091 in max 0 37 mm 0 0146 in Note If the planet carrier has been adjusted with reverse gear brake B1 and free wheel removed then install reverse gear brake B1 before
23. nner and outer B1 plates Install pressure plate with flat side facing plates Thickness of pressure plate varies according to number of plates page 37 65 Install dished washer with convex side facing toward free wheel Note When replacing Transmission housing Free wheel Piston for reverse gear brake B1 or plates Then adjust B1 page 37 98 37 79 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 Carry out check measurement of B1 page 37 105 lt 37 80 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 Center both washers with axial needle bearing between sun gears 37 81 lt Install axial needle bearing and needle bearing in large drive shaft Install large drive shaft with bearing 37 82 Install small drive shaft Install small drive shaft bolt 1 with washer 2 and shim 3 Tightening torque 30 Nm 22 ft Ib Note Install shim 3 onto small drive shaft shoulder arrow Determining shim thickness page 37 90 Planet carrier adjusting Carry out planet carrier check
24. outer plate A The thickness of the outer plate is determined by gap x and is selected from table page 37 118 Gap x a b 3 6mm ii A Outer plate xx o zyr si sa 4 zX i i H Note First outer plate arrow is always 3 mm thick 37 117 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 onto stator support arrow and measure with depth gauge A to gasket of pump flange Example Measurement 40 1 mm Straightedge height 19 5 mm Calculated size b 20 6mm Gap x a b 3 6mm 30 2 20 6 6 00 mm Determine thickness of outer plate according to Table of plates Gap x mm Plate thickness mm table 4 25 4 49 4 50 4 74 4 75 4 99 5 00 5 24 5 25 5 49 5 50 5 74 5 75 5 99 6 00 6 24 6 25 6 49 6 50 6 74 6 75 7 00 Determine thickness of outer plate according to table and determine Part No from parts catalog microfiche 2 75 3 00 3 25 3 50 3 75 2 00 2 00 2 00 2 25 2 25 2 25 2 25 2 50 2 50 2 50 2 50 2 75 37 118 Two outer plates can be installed if necessary to achieve the specified thickness 38 1 ATF pump disassembling and assembling 1 Piston ring Che
25. ps onto compression springs Note When replacing Supporting tube the ATF pump or the plates the 2nd and 4th gear brakes B2 are to be adjusted page 37 113 Replace corrugated washer Replace ATF pump seal Install O ring on ATF pump 37 88 Install ATF pump Tighten bolts evenly alternating cross wise Tightening torque 8 Nm 71 in Ib plus an additional ae turn 90 Additional My turn can be done in several stages Note Make sure that the O ring is not damaged Carry out check measurement of clutch play gt page 37 112 Install sealing plugs valve body and oil pan page 38 36 Install cover with gasket and spacer bushings 37 89 Planetary gearbox adjustments overview e IV Reverse gear brake B1 A Shim Determining thickness Reverse gear brake B1 adjusting page 37 98 2nd and 4th gear brake B2 B Outer plate Determining thickness page 37 113 2nd and 4th gear brake B2 adjusting Planet carrier C Shim Determining thickness page 37 90 Planet carrier adjusting Clutch play D Shim Determining thickness page 37 106 Clutch play between K1 and K2 adjusting 37 90 Planet carrier adjusting Overview of components to adjust planet carrier When adjusting planet carrier install components in transmission housing without shim 17 1 Transmission housing
26. r plates 7 5 mm 0 295 in From transmission build date 17 08 2 With 4 inner plates 11 1 mm 0 437 in With 5 inner plates 7 5 mm 0 295 in Transmissions from 01 93 With 4 inner plates 13 5 mm 0 5371 in With 5 inner plates 10 5 mm 0 413 in Quantity of B1 inner plates from page 00 3 37 66 6 Inner plate B1 Quantity from page 00 3 Before installing place in ATF for 15 minutes 7 Outer plate B1 Quantity from page 00 3 8 Shim Determining thickness page 37 98 Reverse gear brake B1 adjusting Additional 3 7 mm 0 146 in shim for B1 with 4 inner plates up to transmission build date 16 08 2 item 5 37 67 IV Planet carrier and input gear removing and installing Overview page 37 55 Note Disassembling planetary gearbox page 37 70 Assembling page 37 76 1 Planet carrier Modified ratios for transmissions from 01 93 page 00 5 Small sun gear cannot be removed in transmissions from 01 93 Adjusting page 37 90 2 O ring Always replace Insert in planet carrier 3 Axial needle bearing washer 4 Axial needle bearing 37 68 5 Axial needle bearing washer Install smooth side in input gear 6 Transmission housing 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 shi
27. supporting tube 37 60 12 Supporting tube B2 For B2 plate package Length of B2 with 4 inner plates 72 3 mm 2 846 in with 5 inner plates 68 6 mm 2 701 in with 6 inner plates 64 9 mm 2 555 in Quantity of B2 inner plates from page 00 3 Insert so that groove engages in wedge of free wheel 37 61 ll Reverse gear clutch K2 to large sun gear removing and installing Overview page 37 55 Note Disassembling planetary gearbox page 37 70 Assembling page 37 76 1 Reverse gear clutch K2 Disassembling and assembling page 38 23 2 Shim Determining thickness page 37 106 Clutch play between K1 and K2 adjusting 1 or 2 shims can be installed 3 1st to 3rd gear clutch K1 with turbine shaft With ball valve arrow disassembling and assembling page 38 16 Without ball valve for transmissions from 01 93 page 00 5 Disassembling and assembling page 38 16 37 62 4 Axial needle bearing washer 5 Axial needle bearing 6 Axial needle bearing washer Lugs face toward axial needle bearing 7 4th gear clutch K3 with pump shaft With ball valve arrow disassembling and assembling page 38 26 4th gear clutch K3 without ball valve for transmissions from 01 93 page 00 5 disassembling and assembling page 38 26 8 Axial needle bearing with washer Axial needle bearing faces toward small drive shaft
28. ut 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 Gap a approx 3 mm 0 118 in Drive out input gear with VW 771 as far as the stop of the tapered roller bearing inner race Remove VW 771 and remove input gear 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 45 Parking lock disassembling and assembling 1 Drive pinion Number of teeth from page 00 3 Technical data Adjusting page 39 45 Removing Fig 8 2 Transmission housing 3 Screw Tightening torque 12 Nm 9 ft Ib Remove screw before removing or installing bearing supporting ring 12 Install with AKD45600001 sealing compound 39 15 4 Hex nut Tightening torque 250 Nm 184 ft Ib 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 1 If signs of damage exist always replace input gear and output gear together 6 Tapered roller bearing inner race Pulling off Fig 2 Pressing on Fig 3 7 Tapered roller bearing outer race Drive out with drift Pressing in Fig 4 8 Bolt M6 14 Nm 10 ft Ib M8 25 Nm 18 ft Ib
29. ving and installing page 39 23 Differential removing and installing 6 O ring Always replace 7 O ring Always replace 39 36 8 Adjusting ring for tapered roller bearing Removing and installing page 39 23 Differential removing and installing 9 Output shaft drive flange Removing and installing page 39 23 Differential removing and installing 10 Tapered roller bearing outer race Remove and install only when adjusting ring heated Drive out with drift Pressing in Fig 4 11 Tapered roller bearing inner race Pulling off Fig 1 Pressing on Fig 2 12 Speedometer drive bushing Drive off together with speedometer drive gear 13 Drive on with drift 39 37 13 Speedometer drive gear Drive out with drift Fit on together with driver bushing item 12 14 One piece thrust washer Place into differential housing before installing bevel gears 15 Small bevel gears Installing Fig 3 16 Large bevel gears Installing Fig 3 17 Circlip CAUTION Do not remove the circlip until after removing the drive flange as the compression spring is pre tensioned 39 38 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 Fig 5 39 39 lt Fig 1 Pulling off taper
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