4-speed automatic gearbox 01N

Chapter overview

• 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
  3
• 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
  10
• 5.2 Final drive
  10
• 6 Repair instructions
  11
• 6.1 Tools
  11
• 6.2 Gearbox
  11
• 6.3 ATF
  13
• 6.4 Seals and sealing rings
  13
• 6.5 Nuts and bolts
  14
• 6.6 Locking devices
  14
• 6.7 Bearings
  14
• 6.8 Piston rings
  14
• 6.9 Inner plates
  15
• 6.10 Shims
  15
• 6.11 Clutches
  15
• 6.12 Valve body
  15
• 6.13 Electrical components
  15
• 6.14 Guided fault finding, vehicle self-diagnosis and testing
  16
• 7 Repair with an exchange component
  17
• 7.1 General information
  17
• 7.2 Adjustments
  17
• 7.3 Contents of an exchange component
  17
• 7.4 Components of -B1-
  19
• 7.5 Components of -B2-
  19
• 7.6 Clutches
  21
• 7.7 Valve body with ATF strainer
  23
• 8 Fault finding for the automatic 4-speed gearbox
  24
• 8.1 Vehicle cannot drive forwards or backwards
  24
• 8.2 Vehicle will not drive forwards
  25
• 8.3 Vehicle will not reverse
  25
• 8.4 Gearbox oily
  25
• 8.5 Oil or ATF leaks around torque converter
  25
• 8.6 Visible fouling of ATF and/or engine coolant
  26
• 8.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
  26
• 8.8 Gearbox oily only near breather - no other external leaks in gearbox
  26
• 8.9 ATF escaping from breather (only for longitudinally installed gearbox 01N)
  26
• 8.10 Selector mechanism does not move freely
  26
• 8.12 Parking lock does not engage
  27
• 8.14 Final drive noisy
  27
• 8.16 Engine speed drops when driving range is selected
  28
• 8.17 Vehicle does not start or also starts in “R-D-3-2-1”
  28
• 8.18 Vehicle does not start or engine stalls after a short time
  29
• 8.19 Selector lever can be moved from “N” or “P” without brake being operated
  29
• 8.20 Selector lever cannot be moved from “N” or “P” although brake is operated
  29
• 8.21 Shifts occur sporadically or not at all
  29
• 8.22 All shifts are “hard or jolting”
  30
• 8.23 One particular shift is “hard or jolting”
  31
• 8.25 Shifts take “too long”
  31
• 8.26 Hard shifts immediately after repair
  32
• 8.27 Gearbox downshifts at constant vehicle speed without apparent reason
  32
• 8.28 Gearbox does not downshift for kickdown
  32
• 8.29 Gearbox does not shift until it warms up
  33
• 8.30 Gearbox switches to emergency running
  33
• 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)
  35
• 8.37 Selector lever position “D” does not shift to 4th gear
  35
• 8.38 Selector lever position “D” does not shift to 4th gear, mechanical (4M)
  36
• 8.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear
  36
• Torque converter
  37
• 1 Torque converter
  37
• 1.1 Assembly overview
  37
• 1.2 Identification of torque converter
  37
• 1.3 Allocation of torque converter
  38
• 1.4 Removing sleeve bearing from turbine shaft
  38
• 1.5 Draining torque converter
  39
• 1.6 Removing and installing torque converter seal
  41
• 1.7 Checking torque converter
  42
• 1.8 Installing torque converter
  42
• Controls, housing
  43
• 1 Connecting Volkswagen tester and selecting functions
  43
• 2 Carry out basic setting
  45
• 3 Electrical and electronic components and their locations
  46
• 4 Repairing selector mechanism
  54
• 4.1 Checking selector mechanism
  54
• 4.2 Checking operation of the ignition key withdrawal lock
  55
• 4.3 Removing and installing selector lever handle
  56
• 4.4 Dismantling and assembling shift mechanism
  57
• 4.5 Removing and installing selector mechanism cover
  59
• 4.6 Dismantling and assembling selector mechanism cover
  60
• 4.7 Removing and installing pull rod upper part
  62
• 4.9 Removing and installing selector mechanism
  64
• 4.10 Removing and installing selector lever cable
  65
• 4.11 Checking and adjusting selector lever cable
  68
• 4.12 Removing, installing and adjusting locking cable
  69
• 5 Measuring main pressure
  75
• 6 Removing and installing gearbox
  79
• 6.1 Removing gearbox
  81
• 6.2 Installing gearbox
  86
• 6.3 Transporting automatic gearbox
  91
• 6.4 Securing gearbox to assembly stand
  92
• 6.5 Removing and installing left and right gearbox support
  94
• 7 Checking ATF level and topping up
  100
• 7.1 Checking ATF level
  101
• 7.2 Topping up ATF
  103
• 7.3 Draining and filling ATF
  103
• 8 Gearbox with selector elements
  105
• 9 Dismantling and assembling gearbox
  107
• 9.1 Removing and installing ATF lines
  107
• 9.2 Cleaning ATF lines and ATF cooler
  111
• 9.3 Overview - dismantling and assembling planetary gearbox
  111
• 9.4 I - Removing and installing ATF pump to support tube
  112
• 9.5 II - Removing and installing reverse clutch -K2- to large sun gear
  114
• 9.6 III - Removing and installing freewheel and reverse gear brake -B1-
  115
• 9.7 IV - Planet carrier and gearbox housing with input gear and cover
  116
• 9.8 Dismantling planetary gearbox
  118
• 9.9 Assembling planetary gearbox
  125
• 9.10 Installing exchange component
  134
• 9.11 Overview - all planetary gearbox adjustments
  144
• 9.12 Adjusting planet carrier
  146
• 9.13 Adjusting reverse gear brake -B1-
  150
• 9.14 Adjusting clutch play between -K1- and -K2-
  153
• 9.15 Adjusting 2nd and 4th gear brake -B2-
  157
• Gears, control
  165
• 1 Dismantling and assembling ATF pump
  165
• 2 Dismantling and assembling freewheel with -B1- piston
  167
• 3 Dismantling and assembling 1st to 3rd gear clutch -K1-
  169
• 4 Dismantling and assembling reverse gear clutch -K2-
  172
• 5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
  175
• 6 Removing and installing oil pan
  178
• 7 Removing and installing ATF strainer
  180
• 8 Removing and installing valve body
  181
• 8.1 Assembly overview
  181
• 8.2 Dismantling and assembling procedure
  185
• 9 Removing and installing gearbox oil temperature sender G93
  190
• 10 Dismantling and assembling parking lock
  192
• 11 Renewing speedometer sender G22 or driving speed sender G68
  197
• Final drive - differential
  198
• 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
  207
• 3.1 Overview - final drive repair
  207
• 3.2 Removing and installing input gear
  208
• 3.3 Removing and installing pinion shaft
  212
• 3.4 Removing and installing differential
  219
• 3.5 Assembly overview - dismantling and assembling differential
  222
• 3.6 Dismantling and assembling differential (procedure)
  227
• 4 Adjusting final drive
  229
• 4.1 Overview of adjustments
  229
• 4.2 Adjustments to be completed after renewing individual components
  229
• 4.3 Adjusting input gear
  230
• 5 Adjusting pinion shaft and crown wheel
  233
• 5.1 General notes
  233
• 5.2 Adjustment and marking of final drive gear sets
  233
• 5.3 Recommended sequence for new adjustment of final drive gear set
  234
• 5.4 Adjusting pinion shaft
  237
• 5.5 Adjusting crown wheel
  242