Service - Part One
Procedure
- Open hood
- Disconnect and isolate the negative battery cable.
- Remove the battery.
- Disconnect the radiator overflow hose from the radiator filler neck.
- Remove the engine coolant overflow bottle (1).
The bottle is secured to the radiator support by bayonet
style attachments. Remove the coolant recovery container by pulling the coolant bottle upwards off of the radiator fan shroud.
- 3.8L vehicles, remove the exhaust cross over pipe, see repair manual group 26 Exhaust System, Emission Control in ElsaWeb.
- Place a drain pan under the transmission.
- Disconnect the oil cooler lines (1) from transaxle using Trans Cooler Disconnect tool 8875A.
- Allow residual transmission fluid to drain into the drain pan and then move the lines out of the way.
- Remove shift cable (1) from manual valve lever (2).
- Remove the solenoid pack connector (1) at the valve body oil pan.
- Remove the engine coolant heater tube hold down clamp bolt located at the left side of the engine.
- Remove the engine coolant heater tube hold down clamp attached at the front of the engine
- Position the engine coolant heater tube out of the way.
- Remove the three valve body oil pan sound deadener retaining clips (1), and remove the sound deadener (2).
- Take note of each sound deadener stud (1) location (x3) for reference later, and remove each stud.
- Remove the wiring harness retaining clip (2) from the valve body oil pan.
- Remove the top valve body oil pan bolts.
- Raise the vehicle on a hoist.
- If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the left front wheels cap with an appropriate removal tool utilizing the notch located between the wheel and outer edge of the cap. Use care not to damage the wheel coating.
- Remove left front wheel.
- Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering knuckle (2).
- Remove brake caliper and bracket (1) from steering knuckle (2) and rotor (4) as a unit, and hang the assembly out of the way. Use care not to over extend the brake hose.
- Rotate steering fully left, and if equipped, remove the bolt (2) at the ground cable.
- If equipped, remove the ground cable clip (1) at the valve body pan and position the cable (3) away from the valve body pan.
- Position a drain pan under the lower oil pan.
- Loosen the lower oil pan bolts and tap the pan at one corner to break it loose allowing the fluid to drain, and then remove the pan.
- Remove the nuts at the oil filter and discard filter.
- Remove the lower valve body oil pan bolts.
- Remove the valve body oil pan.
- Remove the electrical connector (1) at the valve body.
- Remove the screw (3) at the detent arm (1) and remove arm.
- Remove the 21 valve body to case bolts (1). One valve body bolt is hidden by the manual valve rooster comb.
- Pull the valve body away from the underdrive compounder oil transfer tubes (2).
- Lift up on the valve body to clear the manual valve pin (1) past the slot in the rooster comb.
- Separate the underdrive coumpounder transfer tubes (1) from the underdrive compounder.
- Remove tubes (1).
- Remove transfer gear cover-to-case bolts (2) and remove cover (1).
- Remove the oil scavenger (2).
Note:
The scavenger is secured to the transmission case with small tabs. These tabs break easily. Use extreme care when removing the scavenger from the transmission.
- Grind the staked tabs (3) from the transfer gear (2) (underdrive coumpounder side). Take care not to damage the transfer shaft threads.
- Install the gear holder (2) P/N 9739 onto the transfer gear (3) (underdrive compounder side) and remove the nut.
- Remove the snap ring (1) at the under drive compounder assembly (2).
Note:
The underdrive compounder snap ring is tapered. Note the direction of the snap ring taper before removal so that upon reassembly, it will be installed properly.
- Using an impact driver (2), loosen all transfer gear bearing retainer screws (1).
- Remove the four screws (1) shown.
- Install puller adaptor (1) P/N 9908 to the compounder bearing retainer.
- Install slide hammer P/N C-3752 to puller adaptor P/N 9908 and pull the underdrive compounder assembly (1) from the case.
- Remove the underdrive compounder assembly.
- Remove the slide hammer from the adaptor P/N 9908 and clamp the adaptor into a vise to support the underdrive compounder (3) during the disassembly process.
Note:
The planetary gear set/output hub may still be in the transmission case. If the planetary gear set/output hub is in the transmission, remove it and continue.
- Remove the planetary gear set/output hub (1).
- Remove the helical shim (1).
Note:
If the helical shim is not on the sun gear, it may still be located in the planetary gear set.
It will not be necessary to remove the helical shim from the planetary gear set/output hub.
- Using two small picks (2), remove retaining clip (1) from transfer/underdrive shaft. A new retaining clip will be used during assembly.
- Remove the sun gear from the shaft.
- Remove the split bearing (2) using a small pick.
- Remove the underdrive compounder direct clutch (1) from the low clutch (2).
- Remove the thrust bearing (1) from the transfer shaft.
- Remove the overrunning clutch (1) from the low clutch (2).
- Carefully clamp the underdrive compounder low clutch (2) into a soft jaw vise.
Note:
- Care must be taken not to overtighten the vise as damage to the underdrive compounder low clutch may result.
- Remove puller adapter P/N 9908 (1) from the low clutch.
- Remove remaining fasteners securing the transfer shaft bearing retainer and remove the retainer (2).
- Remove the transfer shaft (1) from the low clutch (2).
- Using a bearing splitter P/N 1130 (VW Tool 15/3) and a press, remove the transfer shaft bearing.
- Using installer P/N 6756 and a press, install the transfer bearing Part. No. 7B0323415 onto the transfer shaft.
- Using press puller P/N C-293-PA, Adaptors P/N 9738 and a press plug P/N 9678, remove compounder transfer gear bearing cone.
- Install the transfer gear bearing cone Part No. 7B0323415 using installer Part No. 6756.
- Using a suitable tool drive the transfer shaft bearing inner race (1) from the transfer shaft bearing retainer (2).
- Using a suitable tool drive the transfer shaft bearing outer race (2) from the transfer shaft bearing retainer (1).
- Install the new bearing inner race into the transfer shaft bearing retainer (2) using Bearing Race Installer 9952 and Handle C4171 (1).
- Install the new bearing outer race into the transfer shaft bearing retainer (2) using Bearing Race Installer 9952 and Handle C4171 (1).
- Install the transfer shaft (1) onto the low clutch (2).
- Lube the transfer shaft and transfer gear bearings with clean ATF Part No. GUS 0001621Q (VW ATF+4).