Automatic gearbox 096

Chapter overview

• Technical data
  1
• 1 Identification of gearbox
  1
• 1.1 Identification of gearbox
  1
• 2 Code letters, gearbox allocation, ratios, equipment
  2
• 2.1 Code letters, gearbox allocation, ratios, equipment
  2
• 3 Capacities
  4
• 3.1 Capacities
  4
• 4 Repair instructions
  4
• 4.1 Repair instructions
  4
• Self diagnosis, Electrical check
  7
• 1 Self-diagnosis function
  7
• 1.1 Self-diagnosis function
  7
• 1.2 Technical data of self-diagnosis
  8
• 1.3 Self-diagnosis - Guide
  8
• 2 Locations of electrical/electronic components
  10
• 2.1 Locations of electrical/electronic components
  10
• 3 Performing self-diagnosis
  21
• 3.1 Performing self-diagnosis
  21
• 3.2 Connecting fault reader V.A.G 1551 and selecting functions
  21
• 3.3 List of selectable functions
  22
• 3.4 Interrogating fault memory
  23
• 3.5 Fault table
  23
• 3.6 Erasing fault memory
  27
• 3.7 Initiating basic setting
  28
• 3.8 Read measured value block
  29
• 3.9 Test table
  30
• 4 Gearbox: Electrical test
  36
• 4.1 Gearbox: Electrical test
  36
• 4.2 Electrical check on multi-pin connector with 38 pins
  37
• 4.3 Test table
  38
• 4.4 Electrical check on multi-pin connector with 68 pins
  42
• 4.5 Test table
  45
• Torque converter
  49
• 1 Torque converter
  49
• 1.1 Torque converter
  49
• 1.2 Identification of torque converter
  49
• 1.3 Draining torque converter
  50
• 1.4 Removing and installing torque converter oil seal
  50
• Controls, Housing
  51
• 1 Servicing shift mechanism
  51
• 1.1 Servicing shift mechanism
  51
• 1.2 Checking shift mechanism
  51
• 1.3 Checking and adjusting selector lever cable
  51
• 1.4 Checking ignition key removal lock (vehicles with ignition key removal lock)
  52
• 1.5 Dismantling and assembling shift mechanism
  53
• 1.7 Dismantling and assembling selector lever (vehicles with ignition key removal lock)
  69
• 1.8 Removing and installing locking cable (vehicles with ignition key removal lock)
  75
• 1.9 Adjusting locking cable (vehicles with ignition key removal lock)
  77
• 2 Checking gearbox
  78
• 2.1 Checking gearbox
  78
• 2.2 Checking shift points
  78
• 2.3 Checking stall speed
  78
• 2.4 Measuring main pressure
  78
• 2.5 Fault finding table for "4-speed automatic gearbox"
  78
• 3 Removing and installing gearbox
  78
• 3.1 Removing and installing gearbox
  78
• 4 Checking and topping up ATF level
  83
• 4.1 Checking and topping up ATF level
  83
• 4.2 Checking ATF level
  83
• 4.3 Topping up ATF
  84
• 5 Gearbox with selector elements
  85
• 5.1 Gearbox with selector elements
  85
• 5.2 Position of selector elements
  86
• 6 Dismantling and assembling gearbox
  87
• 6.1 Dismantling and assembling gearbox
  87
• 6.2 Removing and installing ATF cooler and ATF filler tube
  87
• 6.3 Dismantling and assembling planetary gearbox -Overview-
  88
• 6.4 I - Removing and installing ATF pump to supporting tube
  90
• 6.5 II - Removing and installing reverse gear clutch -K2- to large sun gear
  93
• 6.6 III - Removing and installing free wheel and reverse gear brake -B1-
  96
• 6.7 IV - Planet carrier and gearbox housing with input gear and cover
  98
• 6.8 Dismantling and assembling planetary gearbox
  100
• 6.9 Overview of all planetary gearbox adjustments
  112
• 6.10 Adjusting planet carrier
  113
• 6.11 Adjusting reverse gear brake -B1-
  118
• 6.12 Adjusting clutch play between -K1- and -K2-
  123
• 6.13 Adjusting 2nd and 4th gear brake -B2-
  128
• Gears, Hydraulic controls
  132
• 1 Dismantling and assembling ATF pump
  132
• 1.1 Dismantling and assembling ATF pump
  132
• 2 Dismantling and assembling free wheel with -B1- piston
  135
• 2.1 Dismantling and assembling free wheel with -B1- piston
  135
• 3 Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft
  137
• 3.1 Dismantling and assembling 1st to 3rd gear clutch -K1- with turbine shaft
  137
• 4 Dismantling and assembling reverse gear clutch -K2-
  143
• 4.1 Dismantling and assembling reverse gear clutch -K2-
  143
• 5 Dismantling and assembling 4th gear clutch -K3- with pump shaft
  146
• 5.1 Dismantling and assembling 4th gear clutch -K3- with pump shaft
  146
• 6 Removing and installing valve body
  150
• 6.1 Removing and installing valve body
  150
• 7 Dismantling and assembling parking lock
  157
• 7.1 Dismantling and assembling parking lock
  157
• Final drive, Differential
  163
• 1 Checking oil in final drive
  163
• 1.1 Checking oil in final drive
  163
• 2 Removing and installing oil seal for drive flange
  163
• 2.1 Removing and installing oil seal for drive flange
  163
• 3 Dismantling and assembling final drive
  166
• 3.1 Dismantling and assembling final drive
  166
• 3.2 Repair overview of final drive
  166
• 3.3 Removing and installing input gear
  168
• 3.4 Removing and installing drive pinion
  173
• 3.5 Removing and installing differential
  180
• 3.6 Dismantling and assembling differential
  188
• 4 Adjusting final drive
  194
• 4.1 Adjusting final drive
  194
• 4.2 Overview of adjustments
  194
• 4.3 Adjustments to be completed after replacing individual components
  196
• 4.4 Adjusting drive pinion
  196
• 4.5 Adjusting input gear
  199
• 4.6 Adjusting differential
  200