- With final drive housing/transmission assembly removed from vehicle, clean outside case thoroughly and disassemble in a clean area. When cleaning and wiping parts, use nylon cloth or paper towels. Common shop rags will leave lint that can interfere with transaxle's operation. Mount assembly on repair fixture. Drain ATF from transmission.
CAUTION:
When removing/installing torque converter, DO NOT
rock or tilt converter. This could damage the converter oil seal, stator one-way clutch or other components in torque converter hub.
- Withdraw torque converter from final drive housing using a twisting motion. Set converter aside and cover hub opening. Remove governor cover and gasket. Pull governor from final drive housing. Use a clockwise twisting motion to disengage governor drive gear from gear on transmission annulus gear.
- Turn transmission/final drive assembly so gear oil cannot leak. Remove nuts from transmission-to-final drive studs. Separate transmission from final drive. Drain gear oil from final drive if unit is to be repaired.
NOTE:
Final drive disassembly and reassembly procedures are covered at end of this article.
- Withdraw pump shaft and impeller shaft from transmission. Remove screws retaining separation plate in transmission case. Withdraw plate and gasket. Remove governor drive gear/reverse planetary ring gear assembly from case. See Figure
.
- Withdraw needle bearing and thrust washer from top of reverse (front) planetary gear set. Remove large circlip retaining one-way clutch assembly in case. Fabricate 2 hooks from 3/16" welding rod and use hooks to lift one-way clutch assembly from case. See Fig 1
.
Courtesy of VOLKSWAGEN UNITED STATES, INC.
- Grasp reverse (front) planetary gear set and pull from case along with its thrust washer. Remove first/reverse brake plates (4 fiber and 4 steel), with wave washer, from assembly. Withdraw sun gear, driving shell (with internally toothed washer), forward (rear) planetary gear set and forward clutch as an assembly.
NOTE:
When removing forward clutch assembly, ensure 2 thrust washers and thrust bearing which oil pump rides against are not lost or damaged.
- Remove the 2 forward clutch-to-direct/reverse clutch thrust washers, then withdraw direct/reverse clutch from case. Push second gear brake band servo piston assembly down into transmission case. Remove retaining circlip. Withdraw servo assembly (cover, piston and spring) from case.
- If servo assembly sticks, tap cover with rubber mallet until piston pops out under spring pressure. On opposite side of case, loosen lock nut for second gear band adjusting screw. Remove screw with lock nut and withdraw pushrod. From inside case, withdraw second gear band. Remove bolts from first/reverse gear brake spring plate.
- Withdraw spring plate and springs. Pull driving shell, brake piston and oil pump assembly from case. Position transmission case on bench with oil pan facing upward. Remove pan mount bolts. Withdraw pan and gasket. Remove oil strainer screws from valve body.
NOTE:
An inspection of any foreign matter in the oil pan can indicate the type of problems to look for while disassembling transaxle.
- Remove 11 hex-head mount bolts from valve body. Lift valve body from case. Use care not to lose manual valve. Withdraw accumulator spring and piston from case. If necessary for parts replacement, disassemble parking lock, kickdown and manual valve linkage using Figure
as a guide.