Part 3
- 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.
• 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 no axial play can be measured (0 mm), angle washers => [ (Item 33) Angle washer ] Planetary Gear Component Overview and => [ (Item 29) Angle washer ] Planetary Gear Component Overview are possibly interchanged.
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 different length of bolts.
• Bolt - 6 - is only present on transmissions with hydraulic control "E17".
• On a transmission with hydraulic control "E18/2", 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.
• 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 => [ Left Drive Flange, Seal, and Grooved Ball Bearing ] Left Drive Flange, Seal, and Grooved Ball Bearing.
- Replace O-ring - arrow B - in mounting bracket for left flange shaft.
• Disregard - arrow A -.
- Replace final drive/transmission housing double shaft seal if necessary. Refer to => [ Final Drive/Transmission Housing Seal ] Final Drive/Transmission Housing Seal.
- 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.
• 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. Refer to => [ Right Drive Flange Seal ] Right Drive Flange Seal.
- 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.
• 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.
• 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 => [ Drive Pinion Shaft Seal ] Drive Pinion Shaft Seal.
- 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. Refer to => [ Output Flange/Driveshaft O-Ring ] Output Flange/Driveshaft O-Ring.
- Check whether alignment sleeve - A - is inserted in intermediate flange for front final drive.
- Install new gasket.
• 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.
• 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 => [ Installation dimension for torque
converter, checking ] 01VA Transmission.
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. Refer to => [ ATF, Changing or Filling after Repairs ] [1][2]ATF, Changing or Filling After Repairs.
- Fill axle oil in front final drive and check oil level. Refer to => [ Front Final Drive Gear Oil, Checking ] [1][2]Front Final Drive Gear Oil, Checking.
- Top off axle oil in transfer case and check oil level. Refer to => [ Center Differential Gear Oil, Checking and Filling ] Center Differential Gear Oil, Checking and Filling.
Tightening specifications
