Part 2

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





^ Insert tower "II" - 1 - into transmission housing by hand using turning motions.
^ Make sure that coupling plate splines of sun gear engage into outer splines on cylinder "B", to do so turn input shaft and sun gear.





^ Check tower "II" for proper installation.
^ Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF pump on transmission housing.
^ Dimension - a - = at least 6.0 mm.
^ Adjustment shim may not be installed.





^ Place previous adjustment shim - 1 - on carrier plate "C".
^ Replace 2 rectangular rings on input shaft.
^ Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
^ Make sure that rectangular rings are fully seated all around in the input shaft groove.





^ Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
^ Append axial needle bearing onto ATF supply from rear - 1 -.
^ Closed bearing side faces oil supply.
^ Replace rectangular rings - 3 - and - 4 - on stator shaft.
^ Before inserting, thinly coat rectangular rings on ATF supply with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
^ Make sure that rectangular rings are fully seated all around in stator shaft groove.





^ Engage ends of installed rectangular rings - arrows -, as depicted in illustration.





^ Replace O-ring - 1 - on ATF pump.
^ Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in hydraulic transmission control.





^ Align coated plate - 3 - of clutch "C" using centering tool T10288/1, to do so let pins - 2 - and - 4 - engage in splines of all coated plate.
^ Align coated plate to oil supply housing, insert centering pins - 1 - and - 5 - in corresponding bores on oil supply to do so.
^ Centering pins fit only in one position.
^ Hold centering tool in this position and insert wedge T10288/2 from side between wave washer and piston "F" - arrow -.
^ Wedge must secure all plates in current position.
^ Remove centering tool T10288/1, wedge T10288/2 remains inserted.





^ Align plate carrier for clutch "C" using centering tool T10288/3, screw in guide pins T10288/4 into transmission housing.
^ Bores of centering tool and transmission housing only fit in one position.
^ Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.
^ Plate carrier for clutch "C" may no longer be turned.





^ Attach puller for ATF pump T10286 at stator shaft.
^ Bring ATF pump to installation position.
^ Recess for flange shaft faces underside of transmission (valve body side).
^ Attach ATF pump with corresponding bores onto guide pins T10288/4.
^ Carefully insert ATF pump into transmission housing and push forcefully.
^ Bring ATF pump to final installation position by alternately tightening two opposing attachment bolts each.





^ Remove wedge 10288/2 using hook 3438.
^ Remove Puller for ATF pump T10286.
^ Remove guide pins T10288/4.





^ Insert bolts for ATF supply together with new sealing washers into ATF pump housing.
^ Bolt on ATF pump in sequence - 1 to 9 -.
^ Tightening torque: 10 Nm.





^ 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.
^ To protect against damage, cover input shaft with insulating tape.
^ Move input shaft up and down using pliers, avoid lateral movement while doing so.
^ Read value of axial clearance on input shaft.
^ Specified value: 0.10 to 0.30 mm.
If specified value is not obtained:
^ Remove ATF supply again.





^ Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to table.
^ Measured axial clearance too small: Install respectively thinner shim.
^ Measured axial clearance too large: Install respectively thicker shim.

The following shims are available:





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:





^ Swing transmission on assembly stand.
^ Valve body side points upward.
^ Slide sealing sleeves - 3 - until stop and coil springs - 2 - into bores of transmission housing.
^ Secure coil springs in bores using circlips - 1 -.
^ Slide circlips in bore downward until offset.

CAUTION: 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.





^ Place valve body onto transmission housing without force.
^ Set pin of notched disc - 1 - into groove of selector register - 2 -





^ Hand-tighten bolts - arrows -.

Note:
^ Note different length of bolts.
^ Make sure that electrical wire to Transmission Input Speed (RPM) Sensor G 182 (if present) is not getting pinched between transmission housing and valve body.





^ Tighten bolts in sequence - 1 to 17 -.
^ Tightening torque: 8 Nm.

Note:
^ Bolt - 6 -is present depending on construction version.





^ 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 oil pan sealing surface.





^ Attach circlip - arrow - for wiring harness/harness connector.





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





^ If present, connect electrical harness connector to Transmission Input Speed (RPM) Sensor G182.
^ Clip electrical harness connector into mount of valve body.





^ Replace ATF filter.
^ Attach ATF filter to valve body.
^ Bolt on ATF filter - arrows -
^ Tightening torque: 5 Nm.





Note:
^ 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 gasket for left flange shaft.

Note:
^ Disregard - arrow A

^ If necessary, replace double seal for left flange shaft in transmission housing.





^ 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 in flange shaft.
^ Insert left flange shaft into transmission.

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





^ Tighten bolts on mounting bracket for left flange shaft - arrows -
^ Tightening torque: 23 Nm.

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.





^ Replace O-ring - arrow - in differential cover.
^ If necessary, replace gasket for right flange shaft in differential cover.





^ Carefully insert differential - arrow -.





^ Position differential cover at transmission housing.
^ Tighten bolts on differential cover in 2 stages in the tightening sequence shown as follows:
^ Hand-tighten bolts - 1 -, - 2 - and - 3 -
^ Tighten bolts - 1 to 12 -.
^ Tightening torque: 23 Nm.





^ Tighten bolt for flange shaft - arrow -, secure flange shaft against turning using drift.
^ 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 (outer side of transmission).





^ Attach drive pinion - 2 - onto input shaft until stop.
^ Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 -, as marked when removed, pull back drive pinion - 2 - from input shaft approximately 20 mm to do so.

CAUTION: Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.





^ Check alignment bushing - A - for proper seating when installing.
^ Install new gasket.

Note:
^ Apply thin coat of axle oil on sealing surface before installing gasket to avoid slipping of the gasket
^ Tighten bolts on front final drive cover in 2 stages in the tightening sequence shown as follows:





When tightening bolts by hand, make sure the housing gap between cover and transmission housing decreases evenly around circumference.





Automatic transmission 01V All Wheel Drive:
^ Completely cover splines on end of input shaft - arrow A - with insulating tape without creasing or overlapping the tape to prevent damage to gasket when sliding on drive pinion.

Note:
^ 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 (outer side of transmission).
^ If necessary, replace sealing ring in drive pinion.





^ Attach drive pinion - 2 - onto input shaft until stop.
^ Insert pinion gear - 3 - into transmission housing together with intermediate pinion - 1 -, as marked when removed, pull back drive pinion - 2 - from input shaft approximately 20 mm to do so.
^ If necessary, replace sealing ring for output flange/drive shaft.

CAUTION: Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.





^ Check whether centering sleeve - A - is inserted in intermediate flange for front final drive.
^ Install new gasket.

Note:
^ 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 sealing ring - arrow - can be damaged.





^ Hand-tighten bolts - arrows -

Note:
^ When tightening bolts by hand, make sure the housing gap between intermediate flange for front final drive and transmission housing decreases evenly aft around.

^ Tighten bolts.
^ Tightening torque: 23 Nm.
^ Check whether centering sleeves - A - are inserted in intermediate flange.
^ Install new gasket.

Note:
^ 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 intermediate flange.





^ Attach Torsen differential - arrow - onto output shaft.





^ Attach transfer case housing with installed spur gears and rear output flange to transmission.
^ Hand-tighten bolts for transfer housing - arrows

Note:
^ When tightening bolts by hand, make sure the housing gap between transfer housing and transmission housing decreases evenly aft around.

^ Tighten bolts in diagonal sequence.
^ Tightening torque: 23 Nm.

Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
^ Remove transmission from assembly stand.
^ Insert torque converter and secure so that it cannot fall out.
^ Check installation dimension of torque converter.
^ Check ATF level and top off.
^ Top off axle oil in front final drive and check oil level.
^ Top off axle oil in transfer case and check oil level.

Tightening torques