Technical data
11 Suggestions and criticism of this workshop manual
12 Further information on “automatic gearbox 01N”
32.1 Self-Study Programme on CD ROM
32.2 Design and function of gearbox
32.3 Historical development of this gearbox
33 Gearbox identification
64 Identification codes, engine allocation, ratios, equipment
75 Capacities
105.1 Planetary gear
105.2 Final drive
106 Repair instructions
116.1 Tools
116.2 Gearbox
116.3 ATF
136.4 Seals and sealing rings
136.5 Nuts and bolts
146.6 Locking devices
146.7 Bearings
146.8 Piston rings
146.9 Inner plates
156.10 Shims
156.11 Clutches
156.12 Valve body
156.13 Electrical components
156.14 Guided fault finding, vehicle self-diagnosis and testing
167 Repair with an exchange component
177.1 General information
177.2 Adjustments
177.3 Contents of an exchange component
177.4 Components of -B1-
197.5 Components of -B2-
197.6 Clutches
217.7 Valve body with ATF strainer
238 Fault finding for the automatic 4-speed gearbox
248.1 Vehicle cannot drive forwards or backwards
248.2 Vehicle will not drive forwards
258.3 Vehicle will not reverse
258.4 Gearbox oily
258.5 Oil or ATF leaks around torque converter
258.6 Visible fouling of ATF and/or engine coolant
268.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
268.8 Gearbox oily only near breather - no other external leaks in gearbox
268.9 ATF escaping from breather (only for longitudinally installed gearbox 01N)
268.10 Selector mechanism does not move freely
268.12 Parking lock does not engage
278.14 Final drive noisy
278.16 Engine speed drops when driving range is selected
288.17 Vehicle does not start or also starts in “R-D-3-2-1”
288.18 Vehicle does not start or engine stalls after a short time
298.19 Selector lever can be moved from “N” or “P” without brake being operated
298.20 Selector lever cannot be moved from “N” or “P” although brake is operated
298.21 Shifts occur sporadically or not at all
298.22 All shifts are “hard or jolting”
308.23 One particular shift is “hard or jolting”
318.25 Shifts take “too long”
318.26 Hard shifts immediately after repair
328.27 Gearbox downshifts at constant vehicle speed without apparent reason
328.28 Gearbox does not downshift for kickdown
328.29 Gearbox does not shift until it warms up
338.30 Gearbox switches to emergency running
338.34 Selector lever position “D” or “3” does not shift to 3rd gear, hydraulic (3H)
348.35 Selector lever position “D” or “3” does not shift to 3rd gear, mechanical (3M)
358.36 Selector lever position “D” or “3” does not shift to 3rd gear (not gearbox 001)
358.37 Selector lever position “D” does not shift to 4th gear
358.38 Selector lever position “D” does not shift to 4th gear, mechanical (4M)
368.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear
36Torque converter
371 Torque converter
371.1 Assembly overview
371.2 Identification of torque converter
371.3 Allocation of torque converter
381.4 Removing sleeve bearing from turbine shaft
381.5 Draining torque converter
391.6 Removing and installing torque converter seal
411.7 Checking torque converter
421.8 Installing torque converter
42Controls, housing
431 Connecting Volkswagen tester and selecting functions
432 Carry out basic setting
453 Electrical and electronic components and their locations
464 Repairing selector mechanism
544.1 Checking selector mechanism
544.2 Checking operation of the ignition key withdrawal lock
554.3 Removing and installing selector lever handle
564.4 Dismantling and assembling shift mechanism
574.5 Removing and installing selector mechanism cover
594.6 Dismantling and assembling selector mechanism cover
604.7 Removing and installing pull rod upper part
624.9 Removing and installing selector mechanism
644.10 Removing and installing selector lever cable
654.11 Checking and adjusting selector lever cable
684.12 Removing, installing and adjusting locking cable
695 Measuring main pressure
756 Removing and installing gearbox
796.1 Removing gearbox
816.2 Installing gearbox
866.3 Transporting automatic gearbox
916.4 Securing gearbox to assembly stand
926.5 Removing and installing left and right gearbox support
947 Checking ATF level and topping up
1007.1 Checking ATF level
1017.2 Topping up ATF
1037.3 Draining and filling ATF
1038 Gearbox with selector elements
1059 Dismantling and assembling gearbox
1079.1 Removing and installing ATF lines
1079.2 Cleaning ATF lines and ATF cooler
1119.3 Overview - dismantling and assembling planetary gearbox
1119.4 I - Removing and installing ATF pump to support tube
1129.5 II - Removing and installing reverse clutch -K2- to large sun gear
1149.6 III - Removing and installing freewheel and reverse gear brake -B1-
1159.7 IV - Planet carrier and gearbox housing with input gear and cover
1169.8 Dismantling planetary gearbox
1189.9 Assembling planetary gearbox
1259.10 Installing exchange component
1349.11 Overview - all planetary gearbox adjustments
1449.12 Adjusting planet carrier
1469.13 Adjusting reverse gear brake -B1-
1509.14 Adjusting clutch play between -K1- and -K2-
1539.15 Adjusting 2nd and 4th gear brake -B2-
157Gears, control
1651 Dismantling and assembling ATF pump
1652 Dismantling and assembling freewheel with -B1- piston
1673 Dismantling and assembling 1st to 3rd gear clutch -K1-
1694 Dismantling and assembling reverse gear clutch -K2-
1725 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
1756 Removing and installing oil pan
1787 Removing and installing ATF strainer
1808 Removing and installing valve body
1818.1 Assembly overview
1818.2 Dismantling and assembling procedure
1859 Removing and installing gearbox oil temperature sender G93
19010 Dismantling and assembling parking lock
19211 Renewing speedometer sender G22 or driving speed sender G68
197Final drive - differential
1981 Checking gear oil in final drive
1982 Renewing oil seal for left or right flange shaft
2002.1 Renewing oil seal for left flange shaft
2002.2 Renewing right drive flange oil seal
2023 Dismantling and assembling final drive
2073.1 Overview - final drive repair
2073.2 Removing and installing input gear
2083.3 Removing and installing pinion shaft
2123.4 Removing and installing differential
2193.5 Assembly overview - dismantling and assembling differential
2223.6 Dismantling and assembling differential (procedure)
2274 Adjusting final drive
2294.1 Overview of adjustments
2294.2 Adjustments to be completed after renewing individual components
2294.3 Adjusting input gear
2305 Adjusting pinion shaft and crown wheel
2335.1 General notes
2335.2 Adjustment and marking of final drive gear sets
2335.3 Recommended sequence for new adjustment of final drive gear set
2345.4 Adjusting pinion shaft
2375.5 Adjusting crown wheel
242