4-speed automatic gearbox 099, four-wheel drive

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Location on gearbox
  1
• 1.2 Code letters and date of manufacture of gearbox arrow 1
  1
• 2 Code letters, engine allocation, ratios, equipment
  2
• 3 Identifying rear final drive
  3
• 4 Code letters, engine allocation, ratios, equipment
  4
• 5 Capacities
  5
• 5.1 Planetary gear
  5
• 5.2 Front final drive
  5
• 5.3 Rear final drive
  5
• 6 Overview - power transmission
  6
• 7 Notes on four-wheel drive automatic gearbox 099
  7
• 7.1 Notes on four-wheel drive automatic gearbox 099
  7
• 7.2 Notes on performance tests, brake tests and towing
  8
• 8 Repair instructions
  9
• 8.1 Repair instructions
  9
• Torque converter
  11
• 1 Torque converter
  11
• 1.1 Identification of torque converter
  11
• 1.2 Allocation of torque converter
  11
• 1.3 Removing and installing torque converter oil seal
  14
• 1.4 Draining torque converter
  14
• Controls, housing
  16
• 1 Repairing selector mechanism
  16
• 1.1 Checking selector mechanism
  16
• 1.2 Checking and adjusting selector lever cable
  16
• 1.3 Dismantling and assembling selector mechanism
  17
• 1.4 Removing and installing selector lever cable
  19
• 1.5 Dismantling and assembling selector lever
  23
• 1.6 Adjusting starter inhibitor switch in right-hand drive vehicles
  24
• 2 Routing diagram of pipe and hose lines for freewheel lock
  25
• 2.1 For vehicles up to chassis number 7MZWV004352
  25
• 2.2 For vehicles from chassis number 7MZWV004353 onwards
  26
• 2.3 Removing and installing control element for freewheel lock
  26
• 3 Checking gearbox
  28
• 3.1 Checking shift points
  28
• 3.2 Checking stall speed
  28
• 3.3 Measuring main pressure
  28
• 3.4 Fault finding table for “4-speed automatic gearbox”
  28
• 4 Removing and installing gearbox
  29
• 4.1 Removing and installing gearbox together with bevel box
  29
• 4.2 Removing and installing bevel box
  37
• 4.3 Removing and installing starter bush
  38
• 5 Checking ATF level and topping up
  41
• 5.1 Checking ATF level
  41
• 5.2 Topping up ATF
  43
• 5.3 Renewing ATF
  43
• 6 Gearbox with selector elements
  45
• 7 Dismantling and assembling gearbox
  48
• 7.1 Removing and installing ATF cooler and ATF filler pipe
  48
• 7.2 Dismantling and assembling planetary gearbox -Overview-
  48
• 7.3 I - Removing and installing ATF pump to supporting tube
  49
• 7.4 II - Removing and installing reverse clutch -K2- to large sun gear
  51
• 7.5 III - Removing and installing freewheel and reverse gear brake -B1-
  52
• 7.6 IV - Planet carrier and gearbox housing with input gear and cover
  53
• 7.7 Dismantling and assembling planetary gearbox
  54
• 7.8 Overview of all planetary gearbox adjustments
  67
• 7.9 Adjusting planet carrier
  68
• 7.10 Adjusting reverse gear brake -B1-
  72
• 7.11 Adjusting clutch play between -K1- and -K2-
  76
• 7.12 Adjusting 2nd and 4th gear brake -B2-
  79
• Gears, control
  88
• 1 Dismantling and assembling ATF pump
  88
• 2 Dismantling and assembling freewheel with -B1- piston
  90
• 3 Dismantling and assembling 1st to 3rd gear clutch -K1-
  92
• 4 Dismantling and assembling reverse gear clutch -K2-
  95
• 5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
  98
• 6 Removing and installing valve body
  101
• 7 Dismantling and assembling parking lock
  106
• Final drive - rear differential
  110
• 1 Removing and installing propshaft
  110
• 1.1 Measuring and adjusting distance between propshaft and steering box
  112
• 2 Repairing propshaft
  113
• 3 Checking function of viscous coupling
  119
• 4 Removing and installing viscous coupling
  120
• 4.1 Removing viscous coupling
  120
• 4.2 Installing viscous coupling
  121
• 5 Renewing viscous coupling oil seal in rear final drive (final drive installed)
  123
• 6 Renewing flange shaft or drive flange oil seals (final drive installed)
  124
• 6.1 Renewing oil seal for right flange shaft
  124
• 6.2 Renewing left drive flange oil seal
  125
• 7 Checking oil in rear final drive
  127
• 8 Checking function of freewheel
  128
• 9 Checking function of freewheel lock
  129
• 10 Removing and installing rear final drive
  130
• 10.1 Removing rear final drive
  130
• 10.2 Installing rear final drive
  131
• 11 Dismantling and assembling rear final drive
  133
• 11.1 Removing and installing viscous coupling and pinion housing
  134
• 11.2 Removing and installing differential and freewheel lock
  135
• 11.4 Dismantling and assembling procedure
  138
• 11.5 Modifying gearbox support VW 353
  144
• 12 Dismantling and assembling differential and freewheel
  145
• 12.1 Assembly overview
  145
• 12.2 Dismantling and assembling differential (procedure)
  146
• 12.3 Removing and installing freewheel (procedure)
  149
• 12.4 Dismantling and assembling freewheel (procedure)
  150
• 13 Repairing shaft bevel gear bearing
  152
• 13.1 Assembly overview
  152
• 13.2 Dismantling and assembling procedure
  153
• 14 Repairing bearing for bevel gear with stub shaft
  158
• 14.1 Assembly overview
  158
• 14.2 Dismantling and assembling procedure
  159
• 15.1 General notes
  166
• 15.2 Adjustment and marking of final drive gear sets
  166
• 15.3 Position of shims
  167
• 15.4 Adjustment overview - rear final drive
  167
• 15.5 Determining fitting position of shaft bevel gear (actual values)
  168
• 15.6 Recommended sequence for new adjustment of final drive gear set
  168
• 15.7 Adjusting shaft bevel gear
  169
• 15.8 Adjusting bevel gear
  173
• Final drive - front differential
  178
• 1 Checking oil in front final drive
  178
• 2 Removing and installing front left flange shaft oil seal
  179
• 4 Renewing bevel box output flange oil seal (bevel box removed)
  185
• 5 Dismantling and assembling final drive
  187
• 5.1 Repair overview of final drive
  187
• 5.2 Unbolting and bolting on front bevel box
  188
• 5.3 Removing and installing differential
  190
• 5.4 Removing and installing input gear
  193
• 5.5 Removing and installing drive shaft
  197
• 5.6 Dismantling and assembling differential
  206
• 6 Adjusting front final drive
  214
• 6.1 Overview
  214
• 6.2 Adjusting work when renewing individual components of the front final drive
  218
• 6.3 Adjusting drive shaft
  219
• 6.4 Adjusting input gear
  221
• 6.5 Adjusting differential
  222