A/T - Diagnosis and Repair Using Test Kit and Worksheet
Group: 37Number: 97-01
Date: Feb. 13, 1997
Subject:
Automatic Transmission, Repairing
Model(s):
All with 4 speed automatic (AG4)
Service
For all transmission repairs involving suspected internal damage, US9208 Transmission Test Kit MUST be used in conjunction with the attached "Transmission Diagnosis" worksheet.
Please make copies of the "Transmission Diagnosis" worksheet as necessary.
Note:
^ The Technician MUST fill out The "Transmission Diagnosis" worksheet as completely as possible. This will serve as part of the self authorization process for the work performed.
^ Below are instructions for use of the Transmission Test Plate (incl. in US9208 Transmission Test Kit).
^ After completing "Transmission Diagnosis" worksheet Fax to Volkswagen Product Support at Fax No: 1-800-403-4710.
^ Retain a copy of "Transmission Diagnosis" worksheet in the permanent vehicle file.
Transmission Test Plate, Installing
- Remove valve body and install correct test plate (different for Phase 0/I and Phase II transmissions) with gasket using supplied Allen head bolts.
Note:
Some US 9208-2 Phase II test plates were not stamped with port identification at the quick coupler fittings.
Fitting locations are as shown.
^ Torque Allen head bolts to 10 Nm (7 ft lb.)
- Apply air pressure to the 5 ports in turn on test plate using a cylinder leakdown tester.
- Record readings on "Transmission Diagnosis" worksheet in "Leakdown Check Results" box.
If any reading is above specification listed on worksheet:
^ Phase 0/I transmissions
- Using ratchet and socket on the crankshaft bolt, turn engine over by hand 2 times then:
- Apply 100 PSI minimum air pressure to the port 2 to 3 times for 2 seconds each time then recheck leakage.
- Record readings on "Transmission Diagnosis" worksheet in "Leakdown Check Results" box.
^ Phase II transmissions
- Apply 100 PSI minimum air pressure to the port 2 to 3 times for 2 seconds each time then recheck leakage.
- Record readings on "Transmission Diagnosis" worksheet in "Leakdown Check Results" box.
When procedure applies to vehicles within warranty see the latest SRT Microfiche for applicable Labor Operations and Suggested Repair Times.