Repair Instructions

Repair Instructions
Maximum possible care, cleanliness, and proper tools are essential to ensure successful transmission repairs. Follow all CAUTIONS AND WARNINGS listed.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Repair Manual, are summarized here.

Transmission
When automatic transmission is replaced, VW ATF in planetary transmission, and gear oil in final drive, should be checked and topped up as necessary. Capacities and specifications.
^ When installing transmission ensure dowel pins are installed correctly.

Gaskets, Oil Seals





^ Radial shaft seals. Pack space between sealing edges -arrow with grease before installing.
^ Always install new O-rings.
^ After installation, check ATF level in transmission or gear oil in final drive, adjust to correct level if necessary.

Locking Elements
^ Do not over stretch circlips; replace if necessary.
^ Circlips must be properly seated in grooves.





^ Replace slotted spring pin. Installed position: Groove is longitudinal to force.

Nuts, Bolts
^ Nuts and bolts for attaching covers and housings must be loosened and tightened diagonally.
^ Do not distort particularly sensitive parts, e.g. valve body, and loosen or tighten diagonally in stages.
^ Tightening torques stated apply to unoiled nuts and bolts.
^ Clean threads of bolts that are secured by locking fluid with a wire brush. Then insert bolts with AMV 185 100 A1.
^ Always replace self-locking nuts.

Bearings
^ Install needle bearings with inscribed side (thicker sheet metal) facing the drift.
^ Heat inner races of tapered roller bearings to approx. 100°C (212°F) before inserting.
^ Do not interchange inner and outer races of same size bearings.
^ Always replace tapered roller bearings which are mounted on a shaft together and use bearings from a single manufacturer.
^ Lubricate all bearings in transmission with gear oil before installing. Oil with special care for measuring friction torque.

Shims
^ Measure shims at several points with micrometer. Different tolerances make it possible to obtain exact shim thickness required.
^ Check for signs of burrs or damage. Install only shims which are in perfect condition.

Inner Plates





- Place new inner plates in ATF fluid for 15 minutes before installing.

Valve Body
- Replace valve body if any selector elements are burned.

Clutches
- Disassemble clutches K1, K2 and K3 only for cleaning. If parts are damaged, replace clutch. Determine clutches according to transmission code letters.

On Board Diagnosis (OBD)
- Before performing repairs, determine cause of malfunction with On Board Diagnosis. Refer to Transmission Control System.