Automatic gearbox 01V - 5-speed four-wheel drive

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Identification of gearbox
  1
• 2 Notes on 5-speed automatic gearbox 01V
  1
• 2.1 Notes on 5-speed automatic gearbox 01V
  1
• 3 Code letters, gearbox allocation
  2
• 3.1 Code letters, gearbox allocation
  2
• 4 Rear final drive identification
  4
• 4.1 Rear final drive identification
  4
• 5 Capacities
  6
• 5.1 Capacities
  6
• 6 General repair instructions
  7
• 6.1 General repair instructions
  7
• Torque converter
  10
• 1 Torque converter
  10
• 1.1 Torque converter
  10
• 1.2 Identification of torque converter
  11
• 1.3 Check torque converter
  11
• 1.4 Removing and installing torque converter oil seal
  12
• 1.5 Draining torque converter
  13
• 1.6 Installing torque convertor
  14
• Controls, Housing
  15
• 1 Connecting VAS 5051 and selecting functions
  15
• 1.1 Connecting VAS 5051 and selecting functions
  15
• 2 Locations of electrical/electronic components
  17
• 2.1 Locations of electrical/electronic components
  17
• 3 Servicing gear change mechanism
  32
• 3.1 Servicing gear change mechanism
  32
• 3.2 Checking gear change mechanism
  32
• 3.3 Checking and adjusting selector lever cable
  33
• 3.4 Checking operation of the ignition key withdrawal lock
  36
• 3.5 Removing and installing selector lever handle
  37
• 3.6 Removing and installing gear change mechanism
  39
• 3.7 Dismantling and assembling shift mechanism (layout)
  42
• 3.8 Dismantling and assembling shift mechanism (work sequence)
  53
• 3.9 Removing and installing selector lever lock solenoid -N110-
  62
• 3.10 Removing and installing selector lever cable
  63
• 3.11 Removing and installing locking cable
  67
• 3.12 Adjusting locking cable
  71
• 4.2 Removing and installing gear selector mechanism
  74
• 4.3 Dismantling and assembling selector mechanism
  76
• 5 Removing and installing gearbox
  79
• 5.1 Removing and installing gearbox
  79
• 5.2 Removing and installing gearbox on vehicles with 4-cylinder TDI engine with unit injectors
  79
• 5.3 Removing and installing gearbox on vehicles with 5-cylinder engine
  96
• 5.4 Removing and installing gearbox on vehicles with V6 TDI engine
  111
• 5.5 Removing and installing gearbox on vehicles with V6 petrol engine
  130
• 5.6 Removing and installing gearbox for vehicles with 8-cyl. injection engine
  146
• 5.7 Transporting automatic gearbox
  166
• 5.8 Securing gearbox to assembly stand
  167
• 5.9 Removing and installing left and right-hand gearbox brackets
  169
• 6 Checking ATF level and topping up
  173
• 6.1 Checking ATF level and topping up
  173
• 6.2 Checking ATF level
  174
• 6.3 Topping up ATF
  177
• 6.4 Renewing ATF
  178
• 6.5 Additional ATF check for vehicles with additional ATF cooler
  180
• 7 Power transfer overview, four wheel drive
  182
• 7.1 Power transfer overview, four wheel drive
  182
• 7.2 Position of selector elements with hydraulic control Type E17
  184
• 7.3 Position of selector elements with hydraulic control Type E18/2
  185
• 8 Dismantling and assembling gearbox
  185
• 8.1 Dismantling and assembling gearbox
  185
• 8.2 Removing and installing ATF lines on vehicles with 4-cylinder engine
  186
• 8.3 Removing and installing ATF lines on vehicles with 5-cylinder 110 kW engine
  189
• 8.4 Removing and installing ATF lines on vehicles with 5-cylinder 125 kW engine
  191
• 8.5 Removing and installing ATF lines on vehicles with V6 petrol engine
  193
• 8.6 Removing and installing ATF lines on vehicles with V6 TDI engine
  196
• 8.7 Removing and installing ATF lines on vehicles with 8-cylinder injection engine
  199
• 8.8 Removing and installing additional ATF cooler
  201
• 8.9 Cleaning ATF pipes and ATF cooler
  203
• Gears, Hydraulic controls
  205
• 1 Removing and installing oil pan
  205
• 1.1 Removing and installing oil pan
  205
• 2 Removing and installing ATF strainer
  206
• 2.1 Removing and installing ATF strainer
  206
• 3 Removing and installing valve chest
  207
• 3.1 Removing and installing valve chest
  207
• 3.2 Assembly overview - Valve chest for gearbox with hydraulic control Type E17
  207
• 3.6 Removing and installing internal oil pipe
  235
• 3.8 Renewing gearbox input speed sender -G182-
  237
• 3.9 Removing and installing wiring harness in gearbox
  239
• 3.10 Renewing gearbox oil temperature sender (ATF) -G93-
  241
• 4 Renewing selector shaft seal
  242
• 4.1 Renewing selector shaft seal
  242
• 5 Renewing multi-function switch -F125-
  244
• 5.1 Renewing multi-function switch -F125-
  244
• 6 Renewing speedometer sender -G22- and road speed sender -G68-
  245
• 6.1 Renewing speedometer sender -G22- and road speed sender -G68-
  245
• Final drive, Differential
  247
• 1 Checking oil in front final drive
  247
• 1.1 Checking oil in front final drive
  247
• 2 Servicing front final drive
  249
• 2.1 Servicing front final drive
  249
• 2.2 Renewing seal for right-hand flange shaft
  254
• 2.3 Renewing seal for left-hand flange shaft
  258
• 2.4 Renewing front final drive/gearbox housing seal
  266
• 2.5 Renewing O-ring on cover for front final drive
  271
• 3 Axle oil in transfer gearbox
  275
• 3.1 Axle oil in transfer gearbox
  275
• 3.2 Checking axle oil in transfer gearbox and topping up
  275
• 3.3 Draining axle oil in transfer gearbox or filling after repairs
  277
• 4 Servicing transfer gearbox
  279
• 4.1 Servicing transfer gearbox
  279
• 4.2 Removing and installing transfer gearbox
  287
• 4.3 Renewing seal for rear flange shaft
  291
• 4.4 Renewing seal on intermediate flange for front final drive
  293
• 4.5 Renewing seal in intermediate flange for front final drive
  296
• 4.6 Renewing seal in drive pinion
  297
• 4.7 Renewing needle bearing for gear wheel-2
  300
• 5 Removing and installing propshaft
  304
• 5.1 Removing and installing propshaft
  304
• 5.2 Assembly overview
  304
• 5.3 Dismantling and assembling sequence
  308
• 5.4 Adjusting propshaft
  314
• 6 Renewing seals for flange shafts (rear final drive installed)
  318
• 6.1 Renewing seals for flange shafts (rear final drive installed)
  318
• 7 Renewing seal for propshaft flange (rear final drive installed)
  321
• 7.1 Renewing seal for propshaft flange (rear final drive installed)
  321
• 8 Measuring and marking radial run-out on propshaft flange
  327
• 8.1 Measuring and marking radial run-out on propshaft flange
  327
• 10 Removing and installing rear final drive
  332
• 10.1 Removing and installing rear final drive
  332
• 11 Checking rear final drive oil
  336
• 11.1 Checking rear final drive oil
  336
• 12 Dismantling and assembling rear final drive
  337
• 12.1 Dismantling and assembling rear final drive
  337
• 12.2 Overview
  337
• 13 Removing and installing differential
  339
• 13.1 Removing and installing differential
  339
• 14 Dismantling and assembling differential
  346
• 14.1 Dismantling and assembling differential
  346
• 15 Removing and installing pinion shaft and dismantling and assembling
  359
• 15.1 Removing and installing pinion shaft and dismantling and assembling
  359
• 16 Adjusting pinion shaft and crown wheel
  372
• 16.1 Adjusting pinion shaft and crown wheel
  372
• 16.2 General notes
  372
• 16.3 Adjusting and marking of gear sets
  372
• 16.4 Position of shims
  374
• 16.5 Adjustment overview
  374
• 16.6 Recommended sequence for adjusting gear set
  375
• 16.7 Adjusting pinion shaft
  375
• 16.8 Adjusting crown wheel
  380
• 17 Definitions
  385
• 17.1 Definitions
  385