Part 2
Planetary gear, disassembling and assembling - 5 Spd. A/T 01V Front and All Wheel Drive, continued from part 1
^ Angled edge of angle washer faces down.
- Insert axial needle bearing - 2 -.
- Insert thrust washer - 3 -.
- Insert shaft with ring gear "I" - 4 -.
- Insert thrust washer - 1 - into ring gear "I".
- Insert axial needle bearing - 2 -.
- Place angled washer - 3 -.
^ Angled edge of angle washer faces down.
- Insert planetary gear set "I" and "II" - 1 -.
- Insert sun gear "I" - 1 - in planetary gear set "I" and "II".
Note:
^ Magnetic sun gear for transmission with hydraulic control "E17" (Transmission Input Speed (RPM) Sensor G182 as inductive sensor).
^ Non-magnetic sun gear for transmission with hydraulic control "E1812" (Transmission Input Speed (RPM) Sensor G182 as Hall sensor).
- Insert axial needle bearing - 1 -.
- Assemble the following components as one unit:
1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer - angled edge points downward toward axial needle bearing
5. Intermediate shaft with inner plate carrier
6. Thrust washer
7. Axial needle bearing
8. Thrust washer
- Insert sun shaft - 1 - together with intermediate shaft - 2 - with inner plate carrier.
- Remove "tower II" - 1 - from mounting device T10283 and turn to installation position.
- Insert tower "II" - 1 - into transmission housing by hand using turning motions.
- Ensure sun gear coupling plate splines "I" engage in outer splines on cylinder "B" by turning input shaft and sun gear "I".
- Check tower "II" for proper installation.
- Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF pump on transmission housing.
^ Dimension - a - = at least 6.0 mm.
^ Adjustment shim may not be installed.
- Place previous adjustment shim - 1 - on plate carrier "C".
- Replace 2 rectangular rings on input shaft.
- Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in the input shaft groove.
- Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Append axial needle bearing to ATF pump - 1 -.
^ Closed side of axial needle bearing faces toward ATF pump.
- Replace rectangular rings - 3 - and - 4 - on stator shaft.
- Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in stator shaft groove.
- Engage ends of installed rectangular rings - arrows -, as depicted in illustration.
- Replace O-ring - 1 - on ATF supply.
- Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in hydraulic transmission control.
- Align coated plates - 3 - of clutch "C" using centering tool T10288/1, to do so let pins - 2 - and - 4 - engage in splines of all coated splines.
- Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes on ATF pump.
^ Centering pins fit only in one position.
- Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and piston "F" - arrow -.
^ Wedge must secure all plates in current position.
- Remove centering tool T10288/1, wedge T10288/2 remains inserted.
- Align plate carrier for clutch "C" using centering tool T10288/3, install guide pins T10288/4 into transmission housing.
^ Holes in centering tool and transmission housing only fit in one position.
- Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.
^ Plate carrier for clutch "C" may no longer be turned.
- Attach puller for ATF supply T1 0286 at stator shaft.
- Bring ATF supply to installation position.
^ Recess for flange shaft faces toward valve body side.
- Attach ATF supply with corresponding bores onto guide pins T10288/4.
- Carefully insert ATF supply into transmission housing and push forcefully.
- Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts each.
- Remove wedge 10288/2 using hook 3438.
- Remove Puller for ATF supply T10286.
- Remove guide pins T10288/4.
- Insert ATF pump bolts with new sealing washers into ATF pump housing.
- Tighten ATF pump bolts - 1 to 9 - in sequence.
^ Tightening torque: 10 Nm.
Note:
^ Check for correct ATF pump installation: You must be able to rotate the input shaft. Otherwise, the last clutch plate "C" may have been pinched during installation and bent. In this case, remove ATF pump again and check discs for damage.
- Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
- Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in illustration.
- Set dial gauge to "0".
- To protect against damage, cover input shaft with insulating tape.
- Move input shaft up and down using pliers, while doing so avoid lateral movement.
- Read input shaft axial clearance on dial gauge.
^ Specified value: 0.10 to 0.30 mm.
If specified value is not obtained:
- Remove ATF pump again.
- Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.
^ Measured axial clearance too small: Install respectively thinner shim.
^ Measured axial clearance too large: Install respectively thicker shim.
- Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring
- Check axial clearance of input shaft again.
If specified value is again not obtained:
- Repeat adjustment.
If specified value is obtained:
- Rotate transmission on assembly stand.
^ Valve body side points upward.
- Press sealing sleeves - 3 - into transmission housing holes to stop.
- Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.
CAUTION:
Only transmissions with hydraulic control "E17": Do not rest valve body on Transmission Input Speed (RPM) Sensor G182 arrow - (on bottom side of valve body) - risk of damage.
- Position valve body on transmission housing without force while inserting notched disc pins - 1 - into selector slide groove - 2 -.
- Position valve body bolts.
Note:
^ Note different length of bolts.
^ Bolt - 6 - is only present on transmissions with hydraulic control "E17".
^ On a transmission with hydraulic control "E1812", ensure electrical wire to Transmission Input Speed (RPM) Sensor G182 is not pinched between transmission housing and valve body.
- Tighten valve body bolts in 2 stages as follows:
Replace O-rings for wiring harness/harness connector.
- Connect wiring harness connector - arrow - to transmission housing.
^ Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector must be parallel to ATF oil pan sealing surface.
- Position wiring harness connector securing clip - arrow - and ensure it locks securely.
- Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38 / Transmission Output Speed (RPM) Sensor G195.
^ Tightening torque: 10 Nm.
- With a transmission with hydraulic control "E18/2", connect electrical connector to Transmission Input Speed (RPM) Sensor G182.
- Clip electrical harness connector into valve body mount - arrow -.
- Replace ATF filter.
- Position ATF filter on valve body and tighten - arrows -.
^ Tightening torque: 5 Nm.
Note:
^ Clean magnets (6x) in ATF oil pan.
^ Ensure full surface contact of the magnets in the ATF oil pan.
- Install ATF oil pan - arrow - with new seal.
- Tighten bolts for ATF oil pan in diagonal sequence in stages.
^ Tightening torque: 10 Nm.
- If necessary, replace flange seal for left flange shaft.
- Replace O-ring - arrow B - in mounting bracket for left flange shaft.
Note:
^ Disregard - arrow A -.
- Replace final drive/transmission housing double shaft seal if necessary.
- Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange shaft.
- Insert left flange shaft into transmission.
Note:
^ When sliding on, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.
- Tighten left flange shaft mounting bracket bolts - arrows -
^ Tightening torque: 23 Nm.
CAUTION:
^ Ensure tapered roller bearing outer race and differential adjusting screw do not fall out of final drive cover.
^ Tapered roller bearing outer race must be installed in the same location.
^ The shim must be the correct size and must not be replaced by a shim with a different thickness.
- Clean baffle and tighten it to final drive cover - arrows -.
^ Tightening torque: 10 Nm.
- Replace O-ring - arrow - in final drive cover.
- If necessary, replace flange seal for right flange shaft.
- Carefully install differential - arrow -.
- Position final drive cover on transmission housing.
- Tighten final drive cover bolts in 2 stages as follows:
- Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.
^ Tightening torque: 23 Nm.
Automatic transmission 01V Front Wheel Drive:
- Attach coil spring - 3 - onto pinion shaft.
- Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.
^ Angled edge of axial needle bearing points toward adjustment shim.
- Attach drive pinion - 2 - onto input shaft until stop.
CAUTION:
Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.
- Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 -, as marked when removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.
- Check whether alignment sleeve - A - is inserted in front final drive cover.
- Install new gasket.
Note:
^ Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.
- Tighten front final drive cover bolts in 2 stages as follows:
Automatic transmission 01V All Wheel Drive:
- Completely cover splines on input shaft - arrow A - with insulating tape without creasing or overlapping the tape to prevent damage to gasket when sliding on drive pinion.
Note:
^ Disregard - arrow B -.
- Attach coil spring - 3 - onto pinion shaft.
- Attach axial needle bearing - 2 - and adjustment shim - 1 - onto input shaft.
^ Angled edge of axial needle bearing points toward adjustment shim.
- Replace shaft seal in drive pinion if necessary.
- Attach drive pinion - 2 - onto input shaft until stop.
CAUTION:
Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.
- Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 - as marked when removed, to do so pull back drive pinion - 2 - from input shaft approx. 20 mm.
- If necessary, replace shaft seal for output flange/drive shaft.
- Check whether alignment sleeve - A - is inserted in intermediate flange for front final drive.
- Install new gasket.
Note:
^ Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.
- Carefully place intermediate flange for front final drive.
CAUTION:
When installing the intermediate flange to the input shaft carelessly, the sealing lip of the shaft seal - arrow - can be damaged.
- Tighten front final drive intermediate flange bolts in 2 stages as follows:
- Check whether alignment sleeves - A - are inserted in front final drive intermediate flange.
- Install new gasket.
Note:
^ Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket.
- Slide cleaned solenoid in cast-on holding pocket - B - in front final drive intermediate flange.
- Add 200 ml axle oil to Torsen differential.
- Attach Torsen differential - arrow - onto input shaft.
- Attach transfer case housing with installed spur gears and driveshaft input flange to transmission.
- Tighten transfer case housing bolts in 2 stages as follows:
Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
- Remove transmission from assembly stand.
- Insert torque converter and secure against falling down with Bracket 30-211 A.
- Check installation dimension of torque converter.
CAUTION:
The old transmission should be installed and put into operation as quickly as possible to prevent corrosion on the newly installed components.
- Fill ATF and check ATF level.
- Fill axle oil in front final drive and check oil level.
- Top off axle oil in transfer case and check oil level.
Torque specifications
