Automatic gearbox 01M

Chapter overview

• Technical data
  1
• 1 Suggestions and criticism of this workshop manual
  1
• 2 Further information on “automatic gearbox 01M”
  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
  22
• 5.1 Planetary gearbox
  22
• 5.2 Final drive
  22
• 6 Repair instructions
  23
• 6.1 Tools
  23
• 6.2 Volkswagen testers
  23
• 6.3 Gearbox
  24
• 6.4 ATF
  25
• 6.5 Changing ATF
  26
• 6.6 Seals and sealing rings
  26
• 6.7 Nuts and bolts
  27
• 6.8 Locking devices
  27
• 6.9 Bearings
  27
• 6.10 Piston rings
  27
• 6.11 Inner plates
  28
• 6.12 Shims
  28
• 6.13 Clutches
  28
• 6.14 Valve body
  28
• 6.15 Electrical components
  28
• 6.16 Guided fault finding, vehicle self-diagnosis and testing
  29
• 7 Repair with an exchange component
  30
• 7.1 General information
  30
• 7.2 Adjustments
  30
• 7.3 Contents of an exchange component
  30
• 7.4 Components of -B1-
  32
• 7.5 Components of -B2-
  32
• 7.6 Clutches
  34
• 7.7 Valve body with ATF strainer
  36
• 8 Fault finding for the automatic 4-speed gearbox
  37
• 8.1 Vehicle cannot drive forwards or backwards
  37
• 8.2 Vehicle will not drive forwards
  38
• 8.3 Vehicle will not reverse
  38
• 8.4 Gearbox oily
  38
• 8.5 Oil or ATF leaks around torque converter
  38
• 8.6 Visible fouling of ATF and/or engine coolant
  39
• 8.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
  39
• 8.8 Gearbox oily only near breather - no other external leaks in gearbox
  39
• 8.9 ATF escaping from breather (only for longitudinally installed gearbox 01N)
  39
• 8.10 Selector mechanism does not move freely
  39
• 8.12 Parking lock does not engage
  40
• 8.14 Final drive noisy
  40
• 8.16 Engine speed drops when driving range is selected
  41
• 8.17 Vehicle does not start at all or also starts in “R-D-3-2-1”
  41
• 8.18 Vehicle does not start or engine stalls after a short time
  42
• 8.19 Selector lever can be moved from “N” or “P” without brake being operated
  42
• 8.20 Selector lever cannot be moved from “N” or “P” although brake is operated
  42
• 8.21 Shifts occur sporadically or not at all
  42
• 8.22 All shifts are »hard or jolting«
  43
• 8.23 One particular shift is »hard or jolting«
  44
• 8.25 Shifts take »too long«
  44
• 8.26 Hard shifts immediately after repair
  45
• 8.27 Gearbox downshifts at constant vehicle speed without apparent reason
  45
• 8.28 Gearbox does not downshift for kickdown
  45
• 8.29 Gearbox does not shift until it warms up
  46
• 8.30 Gearbox switches to emergency running
  46
• 8.32 Selector lever position “D”, “3” or “2”, gearbox does not shift to 1st gear
  47
• 8.34 Selector lever position “D” or “3” does not shift to 3rd gear, hydraulic (3H)
  47
• 8.35 Selector lever position “D” or “3” does not shift to 3rd gear, mechanical (3M)
  48
• 8.36 Selector lever position “D” or “3” does not shift to 3rd gear (not gearbox 001)
  48
• 8.37 Selector lever position “D” does not shift to 4th gear
  48
• 8.38 Selector lever position “D” does not shift to 4th gear, mechanical (4M)
  49
• 8.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear
  49
• Torque converter
  50
• 1 Torque converter
  50
• 1.1 Proper handling and installation of torque converter
  50
• 1.2 Identification of torque converter and important differences
  51
• 1.3 Removing sleeve bearing from turbine shaft
  53
• 1.4 Removing and installing torque converter oil seal
  54
• 1.5 Draining torque converter
  55
• Controls, housing
  56
• 1 Connecting Volkswagen tester and selecting functions
  56
• 2 Carry out basic setting
  58
• 3 Electrical and electronic components and their locations
  59
• 4 Repairing selector mechanism
  68
• 4.1 Checking selector mechanism
  68
• 4.2 Checking operation of the ignition key withdrawal lock
  69
• 4.3 Removing and installing selector lever cable
  70
• 4.4 Checking and adjusting selector lever cable
  71
• 4.5 Dismantling and assembling selector mechanism
  72
• 4.6 Removing and installing selector lever handle
  75
• 4.7 Removing and installing selector lever
  77
• 4.9 Removing, installing and adjusting locking cable for ignition key withdrawal lock
  81
• 5 Measuring main pressure
  86
• 6 Removing and installing gearbox - required tools
  90
• 6.1 Modifying support rails VW 457
  91
• 6.2 Removing and installing gearbox
  91
• 6.3 Transporting automatic gearbox
  98
• 6.4 Specified torques
  98
• 6.5 Checking ATF level and topping up
  100
• 6.6 Removing and installing starter bush
  104
• 6.7 Gearbox with selector elements
  105
• 6.8 Securing gearbox to assembly stand
  106
• 7 Dismantling and assembling gearbox
  109
• 7.1 Removing and installing ATF cooler and ATF filler tube
  109
• 7.2 Overview - dismantling and assembling planetary gearbox
  110
• 7.3 I - Removing and installing ATF pump to support tube
  110
• 7.4 II - Removing and installing reverse clutch -K2- to large sun gear
  112
• 7.5 III - Removing and installing freewheel and reverse gear brake -B1-
  113
• 7.6 IV - Planet carrier and gearbox housing with input gear and cover
  114
• 7.7 Dismantling planetary gearbox
  116
• 7.8 Assembling planetary gearbox
  122
• 7.9 Installing exchange component
  131
• 7.10 Overview - all planetary gearbox adjustments
  142
• 7.11 Adjusting planet carrier
  145
• 7.12 Adjusting reverse gear brake -B1-
  149
• 7.13 Adjusting clutch play between -K1- and -K2-
  153
• 7.14 Adjusting 2nd and 4th gear brake -B2-
  157
• Gears, control
  166
• 1 Dismantling and assembling ATF pump
  166
• 2 Dismantling and assembling freewheel with -B1- piston
  169
• 3 Dismantling and assembling 1st to 3rd gear clutch -K1-
  171
• 4 Dismantling and assembling reverse gear clutch -K2-
  174
• 5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft
  177
• 6 Removing and installing oil pan
  180
• 7 Removing and installing ATF strainer
  182
• 8 Removing and installing gearbox oil temperature sender G93
  183
• 9 Removing and installing valve body
  185
• 9.1 Overview - valve chest
  185
• 9.2 Procedure for removing and installing valve body
  188
• 10 Dismantling and assembling parking lock
  194
• Final drive - differential
  199
• 1 Checking gear oil in final drive
  199
• 1.1 Vehicles without inspection plug in final drive
  199
• 1.2 Vehicles with inspection plug in final drive
  199
• 2 Removing and installing final drive oil seals
  201
• 2.1 Right side
  202
• 2.2 Left side
  203
• 3 Dismantling and assembling final drive
  209
• 3.1 Overview - final drive repair
  209
• 3.2 Removing and installing input gear
  210
• 3.3 Removing and installing pinion shaft
  213
• 3.4 Removing and installing differential
  220
• 3.5 Dismantling and assembling differential
  225
• 4 Adjusting final drive
  235
• 4.1 Overview of adjustments
  235
• 4.2 Adjustments to be completed after renewing individual components
  235
• 4.3 Adjusting pinion shaft
  236
• 4.4 Adjusting input gear
  239
• 4.5 Adjusting differential
  240