Overview of All Planetary Gearbox Adjustments
Overview of all planetary gearbox adjustments
I = Reverse gear brake -B1
- A - Shim
- Determining thickness = adjusting reverse gear brake -B1-
II = 2nd and 4th gear brake -B2
- B - Outer plate or shim
- Determining thickness = adjusting 2nd and 4th gear brake -B2-
III = Planet carrier
- C - Shim
- Determining thickness = adjusting planet carrier
IV = Clutch play
- D - Shim
- Determining thickness = adjusting clutch play between -K1 and -K2-
Planet carrier, adjustments
Special tools and equipment
- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- VW 382 Measuring device
- Dial gauge
Overview of components to adjust planet carrier
Note: When adjusting the planet carrier install components in the transmission housing without shim (item 17).
1. Input gear
- Do not remove to adjust planet carrier
- Removing and installing input gear or axial needle bearing for planet carrier
2. Axial needle bearing washer
- Insert smooth side in input gear
3. Axial needle bearing
4. Axial needle bearing washer
5. O-ring
- Insert into planet carrier = Assembling planet carrier
6. Planet carrier
7. Transmission - housing
- With input gear and axial needle bearing
- Axial needle bearing remains in input gear
- If axial needle bearing is damaged = Removing and installing input gear
8. Washer
9. Axial needle bearing
10. Large sun gear
11. Washer
- Insert into large sun gear = Assembling planetary gearbox
12. Axial needle bearing
13. Large drive shaft
14. Axial needle bearing
15. Needle bearing
16. Small drive shaft
17. Shim
- Do not install in planet carrier when adjusting
18. Washer
19. Small drive shaft bolt, 30 Nm
Determining shim -A-
- Install all components (items 2 to 16) to adjust planet carrier into transmission housing.
- Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft.
- Install small input shaft bolt -1- with washer -2- but without shim.
Tightening torque: 30 Nm
- Fit dial gauge in VW 382/7.
- Set up dial gauge so that top of gauge is positioned on bolt head center with 1 mm preload.
- Zero dial gauge.
- Move small input shaft up and take reading.
Example: Reading 2.00 mm
- Determine thickness of shim using table and find Part No. in parts catalog.
Table of shims
Example:
Measured value 2.00 mm = Insert 1.7 mm thick shim
- Remove small input shaft bolt.
- Insert correct shim -3- on small input shaft -arrow-.
- Tighten small input shaft bolt -1- with washer -2-.
Tightening torque 30 Nm.
- Perform planet carrier check measurement.
Planet carrier check measurement
- Insert dial gauge in VW 382/7 and place tip on bolt of small input shaft.
- Move small input shaft up and down and take reading of play on dial gauge.
Play:
min. = 0.23 mm
max. = 0.37 mm
Note: If the planet carrier has been adjusted with the reverse gear brake -B1- and freewheel removed, then before installing the planet carrier install the reverse gear brake -B1-, = Assembling planetary Gearbox.
Reverse gear brake -B1-, adjusting
Special tools and equipment
- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- VW 402 Thrust plate
- Depth gauge
- Straightedge
- Feeler gauges
Overview of components to adjust reverse gear brake -B1-
1. Transmission - housing
- With input gear and planet carrier installed
2. Shim
3. Outer plate -B1
4. Inner plate -B1
5. Pressure plate
- Install with flat side facing plates
- Spare part is allocated according to transmission code letters
6. Dished washer
- Convex side faces toward freewheel
7. Freewheel with -B1- piston
Note: Before removing or installing the freewheel, remove the valve body and take out the sealing plugs, and remove transmission vehicle speed sensor-G38-.
8. Circlip
Determining shim -A- thickness
- For the measuring sequence the transmission housing must be clamped into the assembly stand so that the input gear is facing downward, as illustrated on.
Shim thickness is determined by gap "x" and selected from table.
x = k + I - m
A = Shim
x = Gap I = Position of piston in freewheel
m = Height of plate set including pressure plate
K = Constant = 26.9 mm
"K" is determined by installation height in transmission housing and is not adjustable.
Calculating "I":
- Press piston in direction of arrow as far as stop.
- Place straightedge "A" onto outer race of freewheel.
- Measure to inner edge of piston with depth gauge "B".
Example
Calculating "m":
- Place straightedge "A" on thrust plate.
- Compress set of plates including pressure plate in direction of arrow and measure thickness of plate set with depth gauge "B".
Example:
x= k+ 1/2-m
= 26,9 + 3,6/2 -25, 3 = 3, 4 mm
- Determine size of shims according to table:
Table of shims
- Determine thickness of shims according to table and determine Part No. from parts catalog.
- After determining shim for -B1- perform check measurement.
Reverse gear brake -B1- check measurement
- Install parts up to freewheel and secure with circlip.
- Measure play between plates with feeler gauge "A".
Play:
min. = 1.25 mm
max. = 1.55 mm
Clutch play between -K1 and -K2-, adjusting
Special tools and equipment
- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- VW 387 Universal dial gauge bracket
- Depth gauge
- Straightedge
- Dial gauge
Note: To adjust clutch play install components without shim (item 4) = Assembling planetary gearbox.
1. Transmission - housing
- Planetary gearbox installed up to small input shaft = assembling planetary gearbox
2. Axial needle bearing with washer
- Axial needle bearing faces small input shaft
- Washer faces -K3-
3. 1st to 3rd gear clutch -K1- with 3rd and 4th gear clutch -K3-
- The clutches -K1- and -K3- are pressed together
4. Shim
- Do not install when adjusting clutch play
- 1 or 2 shims can be installed
5. Reverse gear clutch -K2-
Conditions:
- Planet carrier installed and adjusted = Assembling planetary gearbox
- For the measuring sequence the transmission housing must be clamped into the assembly stand so that the input gear is facing downward, as illustrated on.
Determining shim -A-
A- Shim
1. ATF pump
2. Reverse gear clutch -K2
3. 1st to 3rd gear clutch -K1
4. 4th gear clutch -K3
- Calculating thickness of shim. Determine gap "x" and calculate shim thickness.
Gap x = a - b
Calculating "a":
- For the measuring sequence the transmission housing must be clamped into assembly stand so that the input gear is facing downward, as illustrated on.
- Place straightedge "A" onto transmission housing.
- Press -K1- together with -K3- down in direction of arrow and measure distance into -K1- with depth gauge "B".
Example:
Reading 1 = 88.5 mm
- Measure with depth gauge "B" to pump flange on transmission housing.
Example:
Reading 2 = 34.3 mm
= Size measured from pump flange/transmission housing into -K1-.
Calculating "b":
- Place new paper gasket onto ATF pump.
- Place straightedge -B- onto stator support (arrow) and measure with depth gauge -A to gasket of pump flange.
Example:
Gap x = a - b
= 54.2 mm - 51.0 mm = 3.2 mm
- Determine size of shim according to table:
Table of shims
- Determine thickness of shims according to table and determine Part No. from parts catalog.
- Perform clutch play check measurement after installing ATF pump.
Check measurement (clutch play)
The clutch play cannot be measured until the ATF pump has been installed.
- Attach dial gauge holder to transmission housing and place dial gauge on turbine shaft with a preload of 1 mm.
- Move turbine shaft up and down and read of play on dial gauge.
Play:
min. = 0.5 mm
max. = 1.2 mm
2nd and 4th gear brake -B2-, adjusting
Special tools and equipment
- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- 3459 Adjustment tool
- Depth gauge
- Straightedge
Note: To adjust, install components without shim (item 11), without last outer plate (item 10) and without spring caps (item 6).
1. Transmission - housing
2. Circlip
- For supporting tube
3. Supporting tube "B2
- Spare part is allocated according to transmission code letters
- Insert so that notch locates on freewheel wedge
4. Outer plate -B2
- 3 mm thick
5. Spring cap
- Install after installing first outer plate (item 4)
6. Spring cap
- Do not install when adjusting -B2
- Install before installing last outer plate
7. Spring
- Spare part is allocated according to transmission code letters
8. Inner plate -B2
- Quantity
- Spare part is allocated according to transmission code letters
9. Outer plate -B2
- Always install 2 mm thick outer plates
- Quantity
10. Outer plate -B2
- 3 mm thick
- Do not install when adjusting -B2
11. Shim
- Do not install when adjusting -B2
12. Retaining ring
- Inserted with smooth side facing last inner plate (item 8) when adjusting -B2-.
Determining shim(s)
The thickness of the shim(s) is determined by gap x. Use the formula:
Gap x = a - b - 2.65 mm
The measuring points are shown in the illustration to help understanding the formula. Special tool 3459, which exerts a force -F- onto the plate packet via the retaining ring, is not illustrated.
Determining dimension a.
Determining dimension b.
2.65 mm = the amount for settling taken into account by force F.
1. ATF pump
2. Retaining ring
3. Plates for -B2- without last outer plate
4. Supporting tube
Note: First outer plate -arrow- and last outer plate (do not install to measure!) are always 3 mm thick.
Calculating dimension "a":
- Assemble planetary gearbox up to last -B2 inner plate. Last outer plate and shim are not installed.
- Place retaining ring with smooth side onto last inner plate.
- Place 3459 onto retaining ring and turn so that 3 clips align with 3 holes for ATF pump.
- Bolt 3459 to flange for ATF pump with 5 Nm.
The plate packet for -B2- is now pressed together for the measurements.
- Measure from pump flange/transmission housing -arrow- to 3459 with depth gauge.
Dimension a = Height of 3459 in mm -measured value
Example:
- Note calculated value a.
- Remove 3459.
- Remove retaining ring.
Calculating dimension "b":
- Push piston into ATF pump onto stop.
- Place new paper gasket onto ATF pump.
- Place straightedge "B" onto stator support (arrow) and measure with depth gauge "A" to gasket of pump flange.
Example:
- Note calculated value b.
Gap x = a - b - 2.65 mm
Gap x = 27.3 ± 20.3 ± 2.65 mm = 4.35 mm
- Determine size of shim(s) according to table:
Table of shims
- Determine thickness of shim(s) according to table and determine Part No. from parts catalog.
In this example two shims must be installed (each 1.00 mm thick).
- Insert three spring caps onto compression springs.
- Insert last outer plate -3 mm thick-.
- Install correct shim(s) -a-.
- Place retaining ring -b- onto shim(s). Smooth side facing shim.
- Further installation instructions are described.