4-speed automatic gearbox 01N

Kapitelübersicht

• Technical data
  1
• 1 Suggestions and criticism of this workshop manual
  1
• 2 Further information on “automatic gearbox 01N”
  3
• 2.1 Self-Study Programme on CD ROM
  3
• 2.2 Design and function of gearbox
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• 2.3 Historical development of this gearbox
  3
• 3 Gearbox identification
  6
• 4 Identification codes, engine allocation, ratios, equipment
  7
• 5 Capacities
  10
• 5.1 Planetary gear
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• 5.2 Final drive
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• 6 Repair instructions
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• 6.1 Tools
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• 6.2 Gearbox
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• 6.3 ATF
  13
• 6.4 Seals and sealing rings
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• 6.5 Nuts and bolts
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• 6.6 Locking devices
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• 6.7 Bearings
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• 6.8 Piston rings
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• 6.9 Inner plates
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• 6.10 Shims
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• 6.11 Clutches
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• 6.12 Valve body
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• 6.13 Electrical components
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• 6.14 Guided fault finding, vehicle self-diagnosis and testing
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• 7 Repair with an exchange component
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• 7.1 General information
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• 7.2 Adjustments
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• 7.3 Contents of an exchange component
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• 7.4 Components of -B1-
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• 7.5 Components of -B2-
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• 7.6 Clutches
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• 7.7 Valve body with ATF strainer
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• 8 Fault finding for the automatic 4-speed gearbox
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• 8.1 Vehicle cannot drive forwards or backwards
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• 8.2 Vehicle will not drive forwards
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• 8.3 Vehicle will not reverse
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• 8.4 Gearbox oily
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• 8.5 Oil or ATF leaks around torque converter
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• 8.6 Visible fouling of ATF and/or engine coolant
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• 8.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
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• 8.8 Gearbox oily only near breather - no other external leaks in gearbox
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• 8.9 ATF escaping from breather (only for longitudinally installed gearbox 01N)
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• 8.10 Selector mechanism does not move freely
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• 8.12 Parking lock does not engage
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• 8.14 Final drive noisy
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• 8.16 Engine speed drops when driving range is selected
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• 8.17 Vehicle does not start or also starts in “R-D-3-2-1”
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• 8.18 Vehicle does not start or engine stalls after a short time
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• 8.19 Selector lever can be moved from “N” or “P” without brake being operated
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• 8.20 Selector lever cannot be moved from “N” or “P” although brake is operated
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• 8.21 Shifts occur sporadically or not at all
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• 8.22 All shifts are “hard or jolting”
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• 8.23 One particular shift is “hard or jolting”
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• 8.25 Shifts take “too long”
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• 8.26 Hard shifts immediately after repair
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• 8.27 Gearbox downshifts at constant vehicle speed without apparent reason
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• 8.28 Gearbox does not downshift for kickdown
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• 8.29 Gearbox does not shift until it warms up
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• 8.30 Gearbox switches to emergency running
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• 8.34 Selector lever position “D” or “3” does not shift to 3rd gear, hydraulic (3H)
  34
• 8.35 Selector lever position “D” or “3” does not shift to 3rd gear, mechanical (3M)
  35
• 8.36 Selector lever position “D” or “3” does not shift to 3rd gear (not gearbox 001)
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• 8.37 Selector lever position “D” does not shift to 4th gear
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• 8.38 Selector lever position “D” does not shift to 4th gear, mechanical (4M)
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• 8.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear
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• Torque converter
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• 1 Torque converter
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• 1.1 Assembly overview
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• 1.2 Identification of torque converter
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• 1.3 Allocation of torque converter
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• 1.4 Removing sleeve bearing from turbine shaft
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• 1.5 Draining torque converter
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• 1.6 Removing and installing torque converter seal
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• 1.7 Checking torque converter
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• 1.8 Installing torque converter
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• Controls, housing
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• 1 Connecting Volkswagen tester and selecting functions
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• 2 Carry out basic setting
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• 3 Electrical and electronic components and their locations
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• 4 Repairing selector mechanism
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• 4.1 Checking selector mechanism
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• 4.2 Checking operation of the ignition key withdrawal lock
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• 4.3 Removing and installing selector lever handle
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• 4.4 Dismantling and assembling shift mechanism
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• 4.5 Removing and installing selector mechanism cover
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• 4.6 Dismantling and assembling selector mechanism cover
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• 4.7 Removing and installing pull rod upper part
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• 4.9 Removing and installing selector mechanism
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• 4.10 Removing and installing selector lever cable
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• 4.11 Checking and adjusting selector lever cable
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• 4.12 Removing, installing and adjusting locking cable
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• 5 Measuring main pressure
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• 6 Removing and installing gearbox
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• 6.1 Removing gearbox
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• 6.2 Installing gearbox
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• 6.3 Transporting automatic gearbox
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• 6.4 Securing gearbox to assembly stand
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• 6.5 Removing and installing left and right gearbox support
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• 7 Checking ATF level and topping up
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• 7.1 Checking ATF level
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• 7.2 Topping up ATF
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• 7.3 Draining and filling ATF
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• 8 Gearbox with selector elements
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• 9 Dismantling and assembling gearbox
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• 9.1 Removing and installing ATF lines
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• 9.2 Cleaning ATF lines and ATF cooler
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• 9.3 Overview - dismantling and assembling planetary gearbox
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• 9.4 I - Removing and installing ATF pump to support tube
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• 9.5 II - Removing and installing reverse clutch -K2- to large sun gear
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• 9.6 III - Removing and installing freewheel and reverse gear brake -B1-
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• 9.7 IV - Planet carrier and gearbox housing with input gear and cover
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• 9.8 Dismantling planetary gearbox
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• 9.9 Assembling planetary gearbox
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• 9.10 Installing exchange component
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• 9.11 Overview - all planetary gearbox adjustments
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• 9.12 Adjusting planet carrier
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• 9.13 Adjusting reverse gear brake -B1-
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• 9.14 Adjusting clutch play between -K1- and -K2-
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• 9.15 Adjusting 2nd and 4th gear brake -B2-
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• Gears, control
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• 1 Dismantling and assembling ATF pump
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• 2 Dismantling and assembling freewheel with -B1- piston
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• 3 Dismantling and assembling 1st to 3rd gear clutch -K1-
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• 4 Dismantling and assembling reverse gear clutch -K2-
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• 5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
  175
• 6 Removing and installing oil pan
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• 7 Removing and installing ATF strainer
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• 8 Removing and installing valve body
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• 8.1 Assembly overview
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• 8.2 Dismantling and assembling procedure
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• 9 Removing and installing gearbox oil temperature sender G93
  190
• 10 Dismantling and assembling parking lock
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• 11 Renewing speedometer sender G22 or driving speed sender G68
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• Final drive - differential
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• 1 Checking gear oil in final drive
  198
• 2 Renewing oil seal for left or right flange shaft
  200
• 2.1 Renewing oil seal for left flange shaft
  200
• 2.2 Renewing right drive flange oil seal
  202
• 3 Dismantling and assembling final drive
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• 3.1 Overview - final drive repair
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• 3.2 Removing and installing input gear
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• 3.3 Removing and installing pinion shaft
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• 3.4 Removing and installing differential
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• 3.5 Assembly overview - dismantling and assembling differential
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• 3.6 Dismantling and assembling differential (procedure)
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• 4 Adjusting final drive
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• 4.1 Overview of adjustments
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• 4.2 Adjustments to be completed after renewing individual components
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• 4.3 Adjusting input gear
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• 5 Adjusting pinion shaft and crown wheel
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• 5.1 General notes
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• 5.2 Adjustment and marking of final drive gear sets
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• 5.3 Recommended sequence for new adjustment of final drive gear set
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• 5.4 Adjusting pinion shaft
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• 5.5 Adjusting crown wheel
  242