5-speed automatic gearbox four-wheel drive 01V

Chapter overview

• Technical data
  1
• 1 Gearbox identification
  1
• 1.1 Gearbox identification
  1
• 2 Notes on 5-speed automatic gearbox 01V four-wheel drive
  2
• 2.1 Notes on 5-speed automatic gearbox 01V four-wheel drive
  2
• 3 Codes, engine allocations
  3
• 4 Identifying rear final drive
  6
• 4.1 Identifying rear final drive
  6
• 4.2 Codes, gearbox allocations, ratios
  6
• 5 Capacities
  8
• 5.1 Capacities
  8
• 6 General repair notes
  10
• 6.1 General repair notes
  10
• 6.2 »Vorsprung durch Technik«
  13
• Torque converter
  14
• 1 Torque converter
  14
• 1.1 Assembly overview - torque converter
  14
• 1.2 Identification of torque converter
  15
• 1.3 Checking torque converter
  15
• 1.4 Draining torque converter
  15
• 1.5 Removing and installing torque converter oil seal
  16
• 1.6 Installing torque converter
  17
• Controls, housing
  19
• 1 Connecting VAS 5051 and selecting functions
  19
• 1.1 Connecting tester
  19
• 2 Electrical and electronic components and their locations
  21
• 3 Repairing selector mechanism
  29
• 3.1 Checking selector mechanism
  29
• 3.2 Checking and adjusting selector lever cable
  30
• 3.3 Checking operation of the ignition key withdrawal lock
  33
• 3.4 Removing and installing selector lever handle
  34
• 3.5 Removing and installing selector mechanism
  36
• 3.6 Assembly overview - dismantling and assembling selector mechanism
  38
• 3.7 Dismantling and assembling selector mechanism - Assembly sequence
  43
• 3.8 Removing and installing selector lever lock solenoid N110
  49
• 3.9 Removing and installing selector lever cable
  50
• 3.10 Removing and installing locking cable
  54
• 3.11 Adjusting locking cable
  57
• 4 Removing, dismantling and assembling selector mechanism cover
  59
• 4.1 Assembly overview - Dismantling and assembling selector mechanism cover
  59
• 4.2 Removing and installing selector mechanism cover
  60
• 4.3 Dismantling and assembling selector mechanism cover
  61
• 5 Removing and installing gearbox
  64
• 5.1 Removing and installing gearbox for vehicles with 4-cylinder TDI engine with unit injectors
  64
• 5.2 Removing and installing gearbox for vehicles with 5-cylinder engines
  79
• 5.3 Installing and removing gearbox for vehicles with V6 TDI engines
  91
• 5.4 Removing and installing gearbox for vehicles with V6 petrol engine
  108
• 5.5 Removing and installing gearbox (vehicles with 8-cylinder engine)
  124
• 5.6 Transporting automatic gearbox
  141
• 5.7 Securing gearbox to assembly stand
  142
• 5.8 Removing and installing left and right gearbox support
  144
• 6 Checking ATF level and topping up
  151
• 6.1 Checking ATF level
  151
• 6.2 Topping up ATF
  154
• 6.3 Renewing ATF
  155
• 6.4 Additional ATF check in vehicles with additional ATF cooler
  156
• 7 Overview - all-wheel drive power train
  158
• 7.1 Position of selector elements with hydraulic control E17
  159
• 7.2 Position of selector elements with hydraulic control E18/2
  160
• 8 Dismantling and assembling gearbox
  161
• 8.1 Removing and installing ATF lines in vehicles with 4-cylinder engines
  161
• 8.2 Removing and installing ATF lines in vehicles with 5-cylinder 110 kW engine
  162
• 8.3 Removing and installing ATF lines in vehicles with 5-cylinder 125 kW engine
  163
• 8.4 Removing and installing ATF lines in vehicles with V6 TDI engine
  164
• 8.5 Removing and installing ATF lines in vehicles with V6 petrol engine
  165
• 8.6 Removing and installing ATF lines in vehicles with 8-cylinder fuel injection engine
  166
• 8.7 Removing and installing additional ATF cooler
  166
• 8.8 Cleaning ATF lines and ATF cooler
  169
• Gears, control
  170
• 1 Removing and installing oil pan
  170
• 1.1 Removing and installing oil pan
  170
• 2 Removing and installing ATF strainer
  172
• 2.1 Removing and installing ATF strainer
  172
• 3 Removing and installing valve body
  173
• 3.1 Assembly overview - valve body for gearbox with hydraulic control E17
  173
• 3.2 Assembly sequence of valve body for gearbox with hydraulic control E17
  175
• 3.3 Assembly overview - valve body for gearbox with hydraulic control E18/2
  180
• 3.4 Assembly sequence for valve body for gearbox with hydraulic control E18/2
  182
• 3.5 Removing and installing internal oil pipe
  187
• 3.7 Renewing gearbox input speed sender G182
  189
• 3.8 Removing and installing wiring harness in gearbox
  191
• 3.9 Renewing gearbox oil temperature sender (ATF) G93
  193
• 4 Renewing oil seal for selector shaft
  194
• 4.1 Renewing oil seal for selector shaft
  194
• 5 Renewing multifunction switch F125
  197
• 5.1 Renewing multifunction switch F125
  197
• 6 Replacing speedometer sender G22 or vehicle speed sender G68
  199
• 6.1 Renewing sender
  199
• Final drive - rear differential
  201
• 1 Removing and installing propshaft
  201
• 1.1 Assembly overview
  201
• 1.2 Dismantling and assembling procedure
  203
• 1.3 Adjusting propshaft
  208
• 2 Renewing oil seals for flange shafts (rear final drive installed)
  212
• 2.1 Renewing oil seals for flange shafts
  212
• 3 Renewing oil seal for propshaft flange (rear final drive installed)
  217
• 3.1 Renewing oil seal for propshaft flange
  217
• 4 Measuring and marking radial run-out on propshaft flange
  223
• 4.1 Measuring radial run-out on propshaft flange
  223
• 5.1 Measuring radial run-out on propshaft flange
  225
• 6 Removing and installing rear final drive
  227
• 6.1 Removing and installing rear final drive
  227
• 7 Checking gear oil in rear final drive
  231
• 7.1 Checking gear oil in rear final drive
  231
• 8 Dismantling and assembling rear final drive
  232
• 8.1 Overview - gearbox
  232
• 9 Removing and installing differential
  233
• 9.1 Removing and installing differential
  233
• 10 Dismantling and assembling differential
  237
• 10.1 Dismantling and assembling differential
  237
• 11 Removing and installing pinion gear and dismantling and assembling
  246
• 11.1 Removing and installing pinion gear and dismantling and assembling
  246
• 12 Adjusting pinion shaft and crown wheel
  257
• 12.1 General notes
  257
• 12.2 Adjustment and marking of final drive gear sets
  257
• 12.3 Position of shims
  259
• 12.4 Adjustment overview
  259
• 12.5 Recommended sequence for new adjustment of final drive gear set
  260
• 12.6 Adjusting drive pinion
  260
• 12.7 Adjusting crown wheel
  264
• 13 Definitions:
  270
• Final drive - front differential
  275
• 1 Checking oil in front final drive
  275
• 1.1 Checking oil in front final drive
  275
• 2 Repairing front final drive
  277
• 2.1 Renewing seal for right flange shaft
  278
• 2.2 Renewing oil seal for left flange shaft
  282
• 2.3 Replacing front final drive/gearbox housing sealing ring
  289
• 2.4 Renewing O-ring on cover for front final drive
  294
• 3 Axle oil in transfer box
  298
• 3.1 Checking axle oil in transfer box and replenishing
  298
• 3.2 Draining axle oil in transfer box or filling after repairs
  299
• 4 Repairing transfer box
  301
• 4.1 Removing and installing transfer box
  304
• 4.2 Renewing seal for rear flange shaft
  307
• 4.3 Renewing seal on intermediate flange for front final drive
  310
• 4.4 Renewing seal in intermediate flange for front final drive
  312
• 4.5 Renewing oil seal in input pinion
  313
• 4.6 Renewing needle bearing for gear wheel 2
  315