LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Volkswagen >> 1983 >> Rabbit Base, Standard >> Repair and Diagnosis >> Transmission >> Automatic Trans >> A/T - Overhaul >> Transaxle Reassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Transaxle Reassembly

NOTE: For Exploded View of A/T Assembly, See Fig 1 .
Fig 1: Exploded View of A/T Assembly
G00223575Courtesy of VOLKSWAGEN UNITED STATES, INC.
  1. Coat first/reverse brake piston with ATF and install on oil pump housing. Insert brake piston/oil pump assembly into transmission case. Ensure anti-rotation lug for thrust washer of oil pump is facing toward top of case.
  2. Before installing first/reverse gear driving shell, measure overall length to ensure proper component is installed. Shell length is 3.734" (94.90 mm). Install driving shell into case so that tab of shell engages upper groove in transmission case. See Fig 2 .
    Fig 2: Installing 1st-Reverse Gear Shell
    G95J19470Courtesy of VOLKSWAGEN UNITED STATES, INC.
  3. Position low/reverse brake piston return springs on spring plate. Ensure springs have a wire thickness of .039" (1 mm). If necessary, use petroleum jelly to adhere springs to plate. Insert assembly into case with springs downward.
  4. Install plate mount bolts and gradually tighten, in a diagonal pattern, to 61 INCH lbs. (7 N.m). After installation, insert pump driveshaft into oil pump. Turn assembly by hand to ensure parts are not jammed and there is no binding.
  5. Position second gear band in transmission case. With NEW "O" rings installed on servo piston cover and coated with ATF, install second gear servo piston in case. Ensure piston pin engages band end inside case. Using lever, push cover/piston assembly against spring pressure. Install circlip.
  6. Turn transmission case horizontal (servo piston cover pointed down). On opposite side of case, install band adjusting screw push rod. Be sure rod engages band end inside case. Install adjusting screw just enough to hold band in place.
  7. Coat forward clutch-to-direct/reverse clutch thrust washers with petroleum jelly and position on rear end of forward clutch. Install forward clutch into direct/reverse clutch. Make sure that splines on forward clutch drum fully engage splines on direct/reverse clutch lined plates.
  8. With transmission case opening angled downward, install assembled clutch units in case and over neck of oil pump. Use care not to damage pump seal rings. Ensure inner thrust washer, thrust bearing and outer thrust washer are between oil pump piston end and forward clutch.
  9. Rotate transmission case so opening faces upward. Install forward planetary-to-forward clutch thrust bearing into forward clutch. Install forward planetary gear set into ring gear in forward clutch.
  10. Install sun gear (short end first) into gear set. Install driving shell and thrust washer over sun gear. Position thrust washer on underside of reverse planetary gear set. Install gear set into case and onto sun gear.
  11. Install first/reverse brake wave washer in case. Check for proper identification mark of "B1" on first gear inner splined plates. Install 4 fiber lined and 4 steel plates in case alternately, starting with steel plate. If any new fiber plates are used, soak plates in transmission fluid for 15 minutes prior to installation.
  12. Install first gear one-way clutch assembly into transmission case. Using special tool, push clutch downward while rotating reverse planetary gear set clockwise to fully engage parts. With all parts engaged, install one-way clutch-to-case retaining circlip. See Fig 3 .
    CAUTION: With correctly installed components, circlip groove should be uncovered. DO NOT  force in circlip on an incorrectly assembled transmission.
    Fig 3: Installing 1st Gear One-Way Clutch Circlip
    G95A19471Courtesy of VOLKSWAGEN UNITED STATES, INC.
  13. Position needle bearing and thrust washer on rear side of governor drive gear/ring gear assembly. Install unit into transmission case, fully engaging reverse planetary gear set. Install separation plate gasket, with plate, over case studs. Install and tighten plate mount screws.
    NOTE: When adjusting brake band, transmission must be horizontal in order to keep band from slipping or jamming.
  14. Adjust second gear brake band as follows: Tighten band adjusting screw to 7 ft. lbs. (10 N.m). Loosen and retighten adjusting screw to 4 ft. lbs. (5 N.m). From this position, back off screw exactly 2 1/2 turns and tighten lock nut to 14 ft. lbs. (19 N.m).
  15. If case linkage was disassembled, reinstall in case using Figure as an assembly guide. Install NEW seal on accumulator piston (lip pointing toward case). Install piston and spring into case.
  16. Install valve body assembly, making sure manual valve engages manual lever and kickdown valve engages kickdown lever. Install valve body-to-case bolts and tighten from center outward. Install oil pan with NEW gasket.
scientia non olet · About LEMON Manuals