Part 1

Planetary gear, disassembling and assembling, 01V, 5 SPD. A/T

Note:
^ General repair notes.
^ Rules of cleanliness for working on automatic transmissions.
^ Coat O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting.
^ Attach mount and adjustment shims only with Vaseline.
^ Use only ATF or Vaseline in areas near ATF. Other lubricating substances cause functional problems in the hydraulic transmission control.

Disassembling
^ Transmission attached to assembly stand.
^ Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

CAUTION: Wear protective glasses.





^ Remove ATF drain plug - 1 - and allow ATF to drain.

Note:
^ Observe disposal regulations.
^ Rest of ATF remains in the oil pan.

^ Remove torque converter.
^ Allow axle oil to drain in rear final drive.





^ Remove locking bolt - A - and allow axle oil to drain.





Automatic transmission 01V Front Wheel Drive:
^ Loosen and remove bolts on cover for front final drive in sequence - 14 to 1 -.

CAUTION:
^ Slowly and carefully remove cover for front final drive from transmission housing. The spur gears can otherwise fall out of the transmission.
^ Do not reinstall spur gears that have fallen to the ground. The transmission must be replaced in this case.

^ Lift off cover for front final drive.





^ Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.

CAUTION:
^ Intermediate pinion - 1 - and pinion gear - 3 -must be reinserted in the same position to maintain running direction.
^ For this reason, mark installation position of intermediate pinion and pinion gear.

^ Remove pinion gear together with intermediate pinion, pull drive pinion - 2 - slightly toward rear while doing so.
^ Remove drive pinion.





^ Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
^ Remove coil spring - 3 - from pinion shaft.





Automatic transmission 01V All Wheel Drive:
^ Loosen bolts - arrows - of transfer case housing in diagonal sequence.
^ Remove bolts.

CAUTION: Carefully and slowly pull transfer case housing off of transmission toward rear. The Torsen differential could otherwise fall out of the transmission.





^ Remove Torsen differential - arrow - completely from output shaft toward rear.





^ Remove bolts - arrows - at intermediate flange for front final drive.

CAUTION:
^ Slowly and carefully remove intermediate flange for front final drive from transmission housing. The spur gears can otherwise fall out of the transmission.
^ Do not reinstall spur gears that have fallen out. When spur gears have fallen out, transmission must be replaced.

^ Lift off intermediate flange for front final drive.





^ Cover splines completely on end of input shaft - arrow - with insulating tape without creasing or overlapping the tape to prevent damage to seal when sliding off drive pinion - 2 -.
^ Mark installation position of intermediate pinion - 1 - and pinion gear - 3

CAUTION:
^ Intermediate pinion - 1 - and pinion gear - 3 -must be reinserted in the same position to maintain running direction.
^ For this reason, mark installation position of intermediate pinion and pinion gear.

^ Remove pinion gear together with intermediate pinion, pull drive pinion - 2 - slightly toward rear while doing so.
^ Remove drive pinion.





^ Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
^ Remove coil spring - 3 -from pinion shaft.





Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
^ Remove bolt for flange shaft - arrow -, secure flange shaft against turning using drift.
^ Place old oil collecting and extracting device V.A.G 1782 beneath transmission.





^ Pull out right flange shaft.

CAUTION:
^ Slowly and carefully remove differential cover from transmission housing. The Torsen differential could otherwise fall out of the transmission.
^ A differential that has fallen out must not be reinstalled. When differential has fallen out, transmission must be replaced.

^ Remove bolts for differential cover in sequence - 12 to 1 -.
^ Remove differential cover.

CAUTION:
^ Make sure that bearing rings and adjustment shims for differential do not fall out of transmission housing and differential cover.
^ Bearing rings and adjustment shims that have fallen out cannot be relocated with shop equipment.





^ Carefully remove differential - arrow -.





^ Cover splines completely on end of flange shaft - arrow - with insulating tape without creasing or overlapping the tape to prevent damage to double seal when sliding off flange shaft.





^ Remove left drive flange mounting bracket - arrows
^ Pull out left drive flange.

Note:
^ When sliding off, left drive flange must be carefully guided by hand to prevent damage to the double seal in transmission.





^ Remove bolts of ATF oil pan - arrow - in diagonal sequence.
^ Remove ATF oil pan.





^ Remove two bolts - arrows - of ATF filter.
^ Pull ATF filter off of valve body.





^ Remove circlip - arrow - for wiring harness/harness connector.
^ Remove wiring harness/harness connector by pressing inward.





^ Disconnect electrical harness connector - arrow - from Transmission Vehicle Speed Sensor (VSS) G38 or Transmission Output Speed (RPM) Sensor G195.





^ If installed, disengage electrical harness connector from Transmission Input Speed (RPM) Sensor G182 at valve body and disconnect harness connector.





^ Remove bolts - arrows -

CAUTION:
^ Remove only bolts marked with - arrows
^ When removing other bolts, the function of the valve body can be influenced or the valve body splits up.
^ Note the different lengths of the bolts.
^ Do not place removed valve body on Transmission Input Speed (RPM) Sensor G182 (on rear side of valve body, not installed in all versions) risk of damage.

^ Carefully remove valve body from transmission.





^ Pull sealing sleeves - arrows - in inlet bores toward clutches "C", "A", "B", "E" and toward torque converter clutch using extracting handle T10271.





^ Remove 3 securing rings - 1 -.
^ Remove coil springs - 2 -.
^ Pull out sealing sleeves - 3 -, using extracting handle T10271.





^ Swing transmission on assembly stand.
^ ATF supply faces upward.
^ Remove bolts for ATF supply in sequence - 9 to 1 -.
^ Remove bolts with sealing washers.





^ Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.





^ Remove adjustment shim - 1 - and axial needle bearing - 2 -.





^ Lift tower "II" - 1 - out of transmission housing.





^ Twist tower "II" - 1 - and place together with input shaft in mounting device T10283.





^ Remove sun shaft - 1 - with intermediate shaft - 2 -.





^ Disassemble following components:
1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer
5. Intermediate shaft
6. Thrust washer
7. Axial needle bearing
8. Thrust washer





^ Remove axial needle bearing - 1 -.





^ Remove sun gear - 1 -.





^ Remove planetary gear set - 1 -.





^ Remove angle washer - 3 -, axial needle bearing - 2 - and thrust washer - 1 -.





^ Remove shaft with ring gear - 4 -, thrust washer - 3 -, axial needle bearing - 2 - and angle washer - 1 -.





^ Remove ribbed cup - 1 -.





^ Remove circlip - arrow - for tower "I".





^ Turn back knurled nut of lifting device T10287.
^ Insert lifting device into tower "I" until stop.
^ Tighten knurled nut of lifting device in clockwise direction.
^ Check lifting device in tower "I" for proper seating.
^ Lift tower "I" out of transmission housing by hand.





^ Place tower "I" in mounting device T10282.





^ Remove sun gear - 1 - with lower angle washer - 2 -, axial needle bearing - 3 - and upper angle washer - 4 - out of transmission housing.

Note:
^ Upper angle washer - 4 - possibly adheres to underside of tower "I".

Assembling

Note:
^ Always replace seals, gaskets and O-rings.
^ Lubricate 0-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting.
^ Attach mount and adjustment shims only with Vaseline.
^ Use only ATF or Vaseline in areas near ATF. Other lubricating substances cause functional problems in the hydraulic transmission control.





^ Check lifting device in tower "I" for proper seating.
^ Lift tower "I" out of mounting device T10282 by hand and lay aside on workbench.





^ Attach the following components to input shaft of tower "I" - 5 -.
4. Upper angle washer - angled edge points up toward tower "I"
3. Axial needle bearing
2. Lower angle washer - angled edge points toward axial needle bearing
1. Sun gear - outer splines of sun gear must engage in splines of clutch "F"





Automatic transmission 01V Front Wheel Drive:
^ Secure sun gear on input shaft without play, using assembly sleeve T10290, as depicted in illustration, thread stud screw - 1 - into bore identified by "A" - arrow A - and hand-tighten.

CAUTION:
^ Stud screw must not be threaded in bore identified by "B" under any circumstances, or splines will be damaged.
^ Bore "A" points toward sun gear.





Automatic transmission 01V All Wheel Drive:
^ Secure sun gear on input shaft without play, using assembly sleeve T10290, as depicted in illustration, thread stud screw - 1 - into bore identified by "B" - arrow B - and hand-tighten.

CAUTION:
^ Stud screw must not be threaded in bore identified by "A" under any circumstances, or contact surface will be damaged.
^ Bore "A" points toward sun gear.





Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
^ Check whether fitted keys - arrow - are inserted centrally on both sides of cylinder "D/G".





^ Bring tower "I" into installation position.
^ Oil bores - arrows - on cylinder "D/G" face toward underside of transmission (valve body).





^ Insert tower "I" completely into transmission housing.
^ Groove for circlip must be free.
^ Loosen knurled nut and remove lifting device T10287.





^ Carefully insert circlip - arrow - for tower "I" into transmission housing.
^ Make sure that circlip is seated evenly all around in groove of transmission housing, if necessary, drive circlip into groove all around using drift.





^ Loosen stud screw and remove assembly sleeve T10290.

Note:
^ Depicted in the illustration with Automatic Transmission 01V All Wheel Drive.





^ Insert ribbed cup - 1 -.





^ Attach angle washer - 1 - on tower "I".
^ Angled edge points downward.
^ Insert axial needle bearing - 2 -.
^ Insert thrust washer - 3 -.
^ Insert shaft with ring gear - 4 -.





^ Insert thrust washer - 1 - into ring gear.
^ Insert axial needle bearing - 2 -.
^ Place angled washer - 3 -.
^ Angled edge points downward.





^ Insert planetary gear set - 1 -.





^ Insert sun gear - 1 - into planetary gear set.

Note:
^ Sun gear magnetic for transmission with inductive sensor
^ Sun gear non-magnetic for transmission with Camshaft Position (CMP) 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
6. Thrust washer
7. Axial needle bearing
8. Thrust washer





^ Insert sun shaft - 1 - together with intermediate shaft - 2 -.





^ Remove "tower II" - 1 - from mounting device T10283 and turn to installation position.