Servicing automatic gearbox 01V, front-wheel drive and all-wheel drive

Chapter overview

• Technical data
  1
• 1 Vorsprung durch Technik
  1
• 2 Repair instructions
  2
• 2.1 General repair notes
  2
• 2.2 Special tools
  4
• 3 Rules for cleanliness when working on the automatic gearbox
  13
• 4 Frequently occurring faults
  14
• 4.1 No power transmitted in any gear
  14
• 4.2 Hard jolt during shift; individual gears slipping; shifts take too long
  15
• 4.3 Hard jolt during shift, power transmission problems in 4th and 5th gear
  16
• 4.4 ATF leaking between engine and gearbox
  16
• 4.5 Speed-dependent noise with vehicle moving
  17
• Torque converter
  18
• 1 Torque converter
  18
• 1.1 Checking torque converter lock-up clutch
  18
• 1.2 Draining torque converter
  20
• 1.3 Checking torque converter
  20
• Controls, housing
  22
• 1 Securing gearbox to assembly stand
  22
• 2 Dismantling and assembling planetary gearbox
  23
• 2.1 Component overview - planetary gearbox
  23
• 2.2 Dismantling and assembling planetary gearbox
  25
• 3 Dismantling and assembling body “I”
  56
• 3.1 Component overview - body “I”
  56
• 3.2 Dismantling body “I”
  57
• 3.3 Component overview - clutch “F”
  58
• 3.4 Dismantling and assembling clutch “F”
  59
• 3.5 Component overview - clutch “D/G” with freewheel
  62
• 3.6 Dismantling and assembling clutch “D/G” with freewheel
  64
• 3.7 Component overview - planet carrier “III”
  73
• 3.8 Dismantling and assembling planetary drive “III”
  75
• 3.9 Assembling body “I”
  75
• 4 Dismantling and assembling body “II”
  77
• 4.1 Component overview - body “II”
  77
• 4.2 Dismantling body “II”
  78
• 4.3 Component overview - clutch “B”
  79
• 4.4 Dismantling and assembling clutch “B”
  80
• 4.5 Component overview - clutch “A”
  84
• 4.6 Dismantling and assembling clutch “A”
  85
• 4.7 Component overview - clutch “E”
  89
• 4.8 Dismantling and assembling clutch “E”
  90
• 4.9 Assembling body “II”
  95
• 5 Dismantling and assembling clutch “C”
  98
• 5.1 Component overview - clutch “C”
  98
• 5.2 Dismantling and assembling clutch “C”
  99
• Gears, control
  104
• 1 Dismantling and assembling ATF supply unit
  104
• 1.1 Component overview - ATF supply unit
  104
• 1.2 Removing and installing complete ATF supply unit with gearbox assembled
  105
• 1.3 Removing ATF pump from housing for ATF supply unit and installing
  120
• 1.4 Removing and installing housing for ATF supply unit and stator shaft
  124
• 1.5 Removing and installing stator shaft
  128
• 1.6 Renewing oil seal for ATF pump
  129
• 2 Repair work on installed gearbox
  130
• 2.1 Removing and installing valve body
  130
• 2.2 Removing and installing internal oil pipe
  133
• 2.3 Removing and installing gearbox speed sender G38 or gearbox output speed sender G195
  134
• 2.6 Removing and installing wiring harness in gearbox
  137
• 3 Assessment of wear on gearbox components
  139
• 3.1 Assessment of wear by checking ATF for colour and contamination
  139
• 3.2 Clutch “F”
  139
• 3.3 Clutch “D/G” with freewheel
  141
• 3.4 Planet carrier “III”
  144
• 3.5 Clutch “B”
  146
• 3.6 Clutch “A”
  148
• 3.7 Clutch “E”
  150
• 3.8 Clutch “C”
  153
• 3.9 ATF supply unit
  155
• Final drive - front differential
  159
• 1 Repairing front axle drive and transfer box
  159
• 1.1 Removing and installing transfer box with Torsen differential
  159
• 1.2 Component overview - front axle drive and transfer box
  159
• 1.3 Renewing oil seal on output flange for propshaft
  163
• 1.4 Renewing oil seal in intermediate flange for front axle drive
  163
• 1.5 Renewing oil seal in input pinion
  164
• 1.6 Renewing needle bearing for gear wheel 2
  165