Auto. Trans. 010 - Modifications For E-Mode (GROUP 37, NO. 82-01)

WARNING: This page is about the Rabbit L, 2D Hatchback, 1.6 G, which is a different variant/trim than selected.

Publication date: 1982-09-10
Reference number: GROUP 37, NO. 82-01

AUTO. TRANS. 010 - MODIFICATIONS FOR E-MODE

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 37, NO. 82-01, Date of Issue: September 10, 1982

AUTOMATIC TRANSMISSION 010 - MODIFICATIONS FOR E-MODE

Model(s): Volkswagen Rabbit, Jetta (Diesel With Automatic Transmission)

Group: 37 - Automatic Transmission - Controls, Case

Bulletin No.: 82-01

Part Identifier: N/A

Date: September 10, 1982

GENERAL DATA (CHANGES)

Transmission code letters: TD

Torque converter code letter: X

Valve body code letters: CK

GEAR RATIO (CHANGE)

Final drive ratio: 3.13

SELECTOR LEVER CABLE, ADJUSTING

Refer to Fig 1 .

CAUTION: * Before starting to work on any part of electrical system disconnect battery ground strap.

When adjusting cable with engine running always place selector lever at P and set parking brake.

NOTE: Coat all joints on assembling with MOS2 grease.

CAUTION: Do not bend or kink selector lever cable before installing.

Remove console.

Shift selector lever into P.

Loosen clamping nut.

Press shift lever on transmission into P (rear stop).

Tighten nut on cable clamp.

8 N.m (69 in-lb)

ACCELERATOR LINKAGE AND PEDAL CABLE, ADJUSTING

Refer to Fig 2 .

CAUTION: When adjusting cable with engine running always place selector lever at P and set parking brake.

NOTE: Throttle controls must be readjusted when idle or full throttle stop screws have been turned.

ADJUSTING ACCELERATOR CABLE

Place selector lever into P and set parking brake.

Remove plastic injection pump cover.

Check idle and max. engine speeds.

If necessary adjust.

Loosen accelerator pedal cable adjuster (arrow -1-). See Fig 3 .

Unhook cable at lever (arrow -2-). See Fig 3 .

Remove circlip and ball socket on pump lever (arrow). See Fig 4 .

Adjust ball stud travel from idle stop -A- to full throttle stop -B- by moving ball stud in pump lever slot. See Fig 5 .

Travel = 32 +/- 1 mm (1.259 +/- 0.040 in.)

Remove rubber boot (arrow) and loosen adjusting nuts 1 and 2 on throttle cable. See Fig 6 .

Push transmission lever into closed throttle position and pull cable housing in direction of arrow. See Fig 7 .

Make sure engagement spring is not compressed.

In this position, tighten nuts -1- and -2-. See Fig 7 .

Attach ball socket to ball stud and install circlip.

Connect accelerator pedal cable to lever.

Press accelerator pedal into kickdown position.

In this position second person must adjust accelerator cable adjuster -C- so that transmission lever contacts stop (arrow). See Fig 8 .
Make sure kickdown spring is compressed.

Lock accelerator pedal cable adjusting nut.

Make sure accelerator pedal is at stop and cable is free of tension.

ACCELERATOR CABLE, CHECKING

Push pump lever against idle stop.

Engagement spring must not be compressed.

Move transmission lever to closed throttle position.

Press accelerator pedal into full throttle position.

Push pump lever against full throttle stop.

Kickdown spring must not be compressed (no kickdown).

Press accelerator pedal past full throttle point to stop.

Transmission lever must be against stop and kickdown spring compressed -D-. See Fig 9 .

TROUBLESHOOTING E-MODE

In addition to troubles in brochure "Automatic Transmission Troubleshooting", following troubles may occur:

ADDITIONAL AUTOMATIC TRANSMISSION TROUBLES

Trouble	Cause	Remedy
Transmission does not disengage from engine with closed throttleand selector lever in position E	Accelerator cable incorrectly adjusted Selector lever cable incorrectly adjusted Main pressure too high Declutching valve in valve body sticking	Adjust accelerator cable. Adjust selector lever cable. Adjust accelerator cable. Disassemble valve body and check declutch valve.

TRANSMISSION OPERATIONS, CHECKING

CAUTION: All work on vehicle calling for running engine must be done with selector lever at N or P and parking brake applied. Only exceptions are pressure test and stall speed test.

NOTE: For proper transmission operation, engine idle speed, ignition timing, injection pump timing, etc. must be correct.

Poor engine output because of incorrect adjustments or worn parts may give impression of problems with automatic transmission.

Before checking operation, try to find out how problem developed and whether any repairs had been done before.

Trouble is often caused by out of adjustment selector lever cable/accelerator cable, low ATF level or improperly tuned engine.

Before performing tests, do general checks and road test. If problem still exists, proceed with tests.

GENERAL CHECKS

Check engine idle speed, ignition timing, injection pump timing.

Check for leaks (ATF or hypoid oil), external damage, loose or missing screws, etc.

TRANSMISSION FLUID LEVEL, CHECKING

Check that vehicle is level.

Place selector lever in N and apply parking brake.

Idle engine. (ATF must be lukewarm).

Check that ATF level is between two marks on dipstick.

Difference between upper and lower marks is approx. 0.5 ltr (1.0 US pt).

Add ATF fluid if necessary.

CAUTION: Tiny particles, dirt or even lint can clog transmission valves. Use only clean funnel and hose to add ATF and wipe dipstick only with clean lint-free cloth.

Do not overfill, too much fluid will upset operation of transmission.

Check smell and appearance of ATF. Burnt smell may indicate burnt friction linings and trouble in control system.

CAUTION: * Automatic transmission fluids labeled DEXRON or DEXRON II must be used. All makes or brands of DEXRON ATF may be mixed with one another. Do not use additives.

Tiny particles, dirt or even lint can clog transmission valves. Use only clean funnel and hose to add ATF and wipe dipstick only with clean lint-free cloth.

FINAL DRIVE OIL LEVEL, CHECKING

Final drive oil level must be up to edge of oil filler hole.
If level is too high or too low it may indicate transfer of oil between transmission and final drive.

STALL SPEED TEST

NOTE: Check stall speed only if vehicle shows poor performance or poor acceleration.

Engine must be warm.

Connect tachometer (see Repair Groups 23 or 28).

Start engine and hold vehicle firmly with parking brake and foot brake.

Put selector lever in D and depress accelerator pedal briefly to full throttle (max. 5 sec.).

Check that engine now runs between 2555 and 2805 rpm (stall speed).

CAUTION: Do not continue stall speed test longer than time required to read tachometer. Maximum stall speed test time 5 seconds. If necessary to repeat test, wait at least 20 seconds.

NOTE: Normal stall speed will drop 125 rpm per 4000 ft altitude. Stall speed will also drop slightly at high ambient air temperature.

If stall speed is not as specified, refer to troubleshooting table as follows:

STALL SPEED TROUBLESHOOTING

Effect	Cause
Stall speed high	Forward clutch or one-way clutch for 1st gear slipping Note; If stall speed rpm in range D is too high, repeat test in range 1. If stall speed rpm is within specifications one-way clutch for 1st gear is defective. if stall speed rpm is still too high, forward clutch is defective.
Stall speed too low a - if up to 200 rpm below specified figure. b - if more than 200 rpm below specified figure	Poor engine performance (ignition timing, fuel injection compression) Stator one-way clutch defective (replace torque converter)

ROAD TEST

NOTE: Vehicle should be driven in all gear ranges and under all possible road conditions. Do not road test if there is obvious mechanical damage.

SHIFT POINTS IN MPH (KM/H)

Shift	Full Throttle	Kickdown
1-2	21-24 (34-39)	35-37 (56-60)
2-3	50-61 (80-98)	61-62 (98-100)
3-2	33-45 (54-73)	56-58 (90-93)
2-1	16-19 (26-30)	30-33 (49-53)

NOTE: When checking shift points, note that speedometer readings may vary due to permissible manufacturing tolerances.

Note shift points and compare to chart above. Shifts should be smooth and should take place quickly and without lag in power transmission.

Listen for any sign of engine speedup between shifts which indicates slipping brake bands or clutches.

After road test, check transmission for fluid leaks.

NOTE: If shift points are incorrect or transmission does not kick down, check accelerator linkage/pedal cable adjustments.

MAIN PRESSURE TEST

NOTE: Main pressure test only if defect cannot be found during other checks. This test will locate defects in ATF circuit (internal leakage, wear, sticking control valves or dirt in ATF system).

Gauge connection (arrow). See Fig 10 .

Connect gauge with 0 - 10 bar (0 - 145 psi) scale.

Measure three different main pressures as follows:

MAIN PRESSURE

Selector Lever Position

Accelerator Pedal Position

Main Pressure bar (psi)

Test Conditions

idle speed

2.90-3.00 (42-44)

Accelerate up to over 50 km/h (31 mph), release gas pedal (idle speed) and checkpressure on gauge.⁽¹⁾

full throttle

5.85-5.95 (85-86)

⁽¹⁾

idle speed

9.00-10.00 (131-145)

Vehicle stationary.

⁽¹⁾	= These tests should be performed on dynamometer.

If specified values are not reached, check following:

MAIN PRESSURE FAULTS & REMEDIES

Fault	Remedy
Oil pump defective	Check pump for wear, replace if necessary.
Oil leaks at seals and sealing surfaces or leakage in housing	Check for leaks, particularly at valve body transfer plate.
Sticking control valve	Disassemble and clean valve body, check valves for free movement.

CLUTCH AND BRAKE BAND OPERATION

This table shows which shift components are in operation in various gears.

It provides basis for determining which shift components are not working properly when complaints are made of poor acceleration, faulty shifting or general transmission defects.

EXAMPLE: No drive in 3rd and R gears. Possible cause: D+R clutch does not work (must be applied).

CLUTCH AND BRAKE BAND OPERATION

Selector Lever Position	1	2 or D	2 or D	D	R
Gears	1st	1st	2nd	3rd	Reverse
Forward clutch	applied	applied	applied	applied	released
D + R clutch	released	released	released	applied	applied
1st + R gear brake plate	applied	released	released	released	applied
2nd gear brake band	released	released	applied	released	released
One-way clutch	inactive	holding	overrun	overrun	inactive