Automatic gearbox 001

Chapter overview

• Technical data
  1
• 1 Suggestions and criticism, general repair notes
  1
• 1.1 Suggestions and criticism of this workshop manual
  1
• 1.2 General repair notes
  2
• 1.3 Tools
  2
• 1.4 Gearbox
  2
• 1.5 ATF
  3
• 1.6 Seals and sealing rings
  4
• 1.7 Nuts and bolts
  4
• 1.8 Locking devices
  5
• 1.9 Bearing
  5
• 1.10 Piston rings
  5
• 1.11 Inner plates
  5
• 1.12 Shims
  5
• 1.13 Clutches
  6
• 1.14 Brakes
  6
• 1.15 Valve body
  6
• 1.16 Electrical components
  6
• 1.17 Guided fault finding, vehicle self-diagnosis and testing
  7
• 2 Fault finding for the automatic 4-speed gearbox
  8
• 2.1 Vehicle cannot drive forwards or backwards
  8
• 2.2 Vehicle will not drive forwards
  9
• 2.3 Vehicle will not reverse
  9
• 2.4 Gearbox oily
  9
• 2.5 Oil or ATF leaks around torque converter
  9
• 2.6 Visible fouling of ATF and/or engine coolant
  10
• 2.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
  10
• 2.8 Gearbox oily only near breather - no other external leaks in gearbox
  10
• 2.9 ATF escaping from breather (only for longitudinally installed gearbox 01N)
  10
• 2.10 Selector mechanism does not move freely
  10
• 2.12 Parking lock does not engage
  11
• 2.14 Final drive noisy
  11
• 2.15 Performance - jolting in neutral or during certain engine and gearbox movements
  12
• 2.16 Engine speed drops when driving range is selected
  12
• 2.17 Vehicle does not start at all or also starts in „R-D-3-2-1“
  12
• 2.18 Vehicle does not start or engine stalls after a short time
  13
• 2.19 Selector lever can be moved from „N“ or „P“ without brake being operated
  13
• 2.20 Selector lever cannot be moved from „N“ or „P“ although brake is operated
  13
• 2.21 Shifts occur sporadically or not at all
  13
• 2.22 All shifts are »hard or jolting«
  14
• 2.23 One particular shift is »hard or jolting«
  15
• 2.25 Shifts take »too long«
  15
• 2.26 Hard shifts immediately after repair
  16
• 2.27 Gearbox downshifts at constant vehicle speed without apparent reason
  16
• 2.28 Gearbox does not downshift for kickdown
  16
• 2.29 Gearbox does not shift until it warms up
  17
• 2.30 Gearbox switches to emergency running
  17
• 2.32 Selector lever position „D“, „3“ or „2“, gearbox does not shift to 1st gear
  18
• 2.34 Selector lever position „D“ or „3“ does not shift to 3rd gear, hydraulic (3H)
  18
• 2.35 Selector lever position „D“ or „3“ does not shift to 3rd gear, mechanical (3M)
  19
• 2.36 Selector lever position „D“ or „3“ does not shift to 3rd gear (not gearbox 001)
  19
• 2.37 Selector lever position „D“ does not shift to 4th gear
  19
• 2.38 Selector lever position „D“ does not shift to 4th gear, mechanical (4M)
  20
• 2.39 Selector lever position „R“, automatic gearbox does not shift to reverse gear
  20
• 3 Gearbox identification
  21
• 3.1 Location on gearbox
  21
• 4 Identification codes, engine allocation, ratios, equipment
  22
• 5 Capacity
  23
• 5.1 Planetary gearbox and final drive
  23
• Torque converter
  24
• 1 Torque converter
  24
• 1.1 Identification of torque converter
  24
• 1.2 Draining torque converter
  24
• 1.3 Removing and installing torque converter oil seal
  25
• 1.4 Installing torque converter
  26
• Controls, housing
  27
• 1 Connecting Volkswagen tester and selecting functions
  27
• 2 Carry out basic setting
  29
• 3 Electrical and electronic components and their locations
  30
• 3.1 Components in vehicle
  30
• 3.2 Components on gearbox
  32
• 3.3 Adjusting multifunction switch F125
  34
• 3.4 Removing and installing senders G38 and G68
  34
• 3.5 Removing and installing wiring harness
  35
• 4 Repairing selector mechanism
  37
• 4.1 Checking selector mechanism
  37
• 4.2 Checking and adjusting selector lever cable
  38
• 4.3 Checking operation of the ignition key withdrawal lock
  38
• 4.4 Dismantling and assembling selector mechanism
  39
• 4.5 Removing and installing selector lever lock solenoid N110
  42
• 4.6 Removing and installing selector lever cable
  43
• 4.7 Removing and installing selector lever
  45
• 4.8 Removing and installing locking cable
  48
• 4.9 Adjusting locking cable
  49
• 5 Removing and installing gearbox
  51
• 5.1 Removing gearbox
  52
• 5.2 Transporting automatic gearbox
  57
• 5.3 Installing gearbox
  58
• 5.4 Specified torques
  59
• 6 Checking ATF level and topping up
  60
• 6.1 Checking ATF level
  61
• 6.2 Topping up ATF
  63
• 6.3 Draining and filling ATF
  63
• 7 Gearbox with selector elements
  65
• 7.1 Position of selector elements
  65
• 7.2 Position of selector elements
  66
• 8 Dismantling and assembling gearbox
  69
• 8.1 Removing and installing ATF cooler and ATF filler tube
  69
• 8.2 Overview - dismantling and assembling planetary gearbox
  69
• 8.3 I - Removing and installing ATF pump up to large sun gear
  70
• 8.4 II - Removing and installing gearbox housing cover up to input gear
  72
• 8.5 Dismantling and assembling planetary gearbox
  74
• 8.6 Overview - all planetary gearbox adjustments
  88
• 8.7 Adjusting reverse gear brake B1
  89
• 8.8 Adjusting 2nd and 4th gear brake B2
  91
• 8.9 Adjusting clutch play
  93
• Gears, control
  98
• 1 Dismantling and assembling ATF pump
  98
• 2 Dismantling and assembling freewheel
  100
• 3 Dismantling and assembling 1st to 3rd gear clutch K1
  101
• 4 Dismantling and assembling reverse gear clutch K2
  104
• 5 Dismantling and assembling 3rd and 4th gear clutch K3
  106
• 6 Dismantling and assembling reverse gear brake B1
  109
• 7 Dismantling and assembling piston for 2nd and 4th gear brake B2
  111
• 8 Removing and installing valve body
  113
• 9 Dismantling and assembling parking lock
  116
• Final drive - differential
  119
• 1 Renewing oil seals for flange shafts
  119
• 1.1 Removing and installing left flange shaft
  119
• 1.2 Removing and installing right flange shaft
  120
• 2 Dismantling and assembling final drive
  122
• 2.1 Overview - final drive repair
  122
• 2.2 Removing and installing differential
  123
• 2.3 Removing and installing pinion shaft
  124
• 2.4 Dismantling and assembling differential
  127
• 3 Adjusting final drive
  132
• 3.1 Overview of adjustments
  132
• 3.2 Adjustments to be completed after renewing individual components
  132
• 3.3 Adjusting differential
  133
• 3.4 Adjusting pinion shaft
  135
• 4 Definitions:
  138