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Transaxle Reassembly: Transaxle

NOTE: Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation. Apply assembly lubrication to all bushings, washers, shims and bearings before installation. See Figure.
  1. Input transfer gear, drive pinion and differential assemblies should be adjusted and installed at this time. Install axial needle bearing to input transfer gear. See Fig 1. Install "O" ring and planetary carrier. On early 1993, install small sun gear. On all, install axial needle bearing and washers. See Figure and Fig 2 . Install the end plate shim for reverse brake clutch plates. See Fig 3.
  2. Install the reverse brake clutch plates. See Fig 4. See BRAKE CLUTCH PLATE APPLICATIONS  table. Using Assembly Ring (VW 3267), install one-way clutch and secure using a circlip. See Fig 5 and Fig 6 .
  3. Using a feeler gauge, check installed reverse brake clutch clearance. See Fig 7. Clearance should be .047-.071" (1.2-1.8 mm). If clearance is not as specified, replace end plate shim. End plate shims are available in thicknesses ranging from .04" (1.0 mm) to .07" (1.9 mm) in .004" (.10 mm) increments.
    Fig 1: Installing Axial Needle Bearing To Input Transfer Gear
    G95D19292Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 2: Installing Planetary Carrier & Axial Needle Bearing
    G93H22498Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 3: Exploded View Reverse Brake Clutch Assembly
    G95E19293Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 4: Installing Reverse Brake Clutch Plates
    G93I22499Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 5: Installing One-Way Clutch
    G93B22500Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 6: Installing Circlips
    G93C22501Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 7: Checking Reverse Brake Clutch Clearance
    G93D22502Courtesy of VOLKSWAGEN UNITED STATES, INC.
    BRAKE CLUTCH PLATE APPLICATIONS

    Application Number Of Plates
    Reverse Clutch
    Inner 5
    Outer 5
    2nd-4th Clutch
    Inner 6
    Outer 7
  4. Install rubber oil splash shield and lower circlip for support tube. See Fig 6. Install washers, bearing and large sun gear. Install large sun gear drive shell. See Fig 8.
  5. Install small sun gear drive shell. Install small planetary drive shaft. See Figure, Fig 9 and Fig 10 . Using a screwdriver, lock small sun gear drive shell to large sun gear drive shell. See Fig 11. Install adjustment shim, washer and bolt on end of small planetary drive shaft. Tighten bolt to 22 ft. lbs. (30 N.m).
  6. Ensure end play is .009-.014" (.23-.37 mm). If end play is not as specified, recheck assembly or adjustment. See PLANETARY CARRIER  under COMPONENT DISASSEMBLY & REASSEMBLY.
    Fig 8: Installing Large Sun Gear Drive Shell
    G93E22503Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 9: Installing Small Sun Gear Drive Shell
    G93F22504Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 10: Installing Small Planetary Drive Shaft
    G93G22505Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 11: Holding Small Sun Gear Drive Shell
    G93F22413Courtesy of VOLKSWAGEN UNITED STATES, INC.
  7. Install bearing, washer, and impeller shaft and 3rd-4th apply clutch. See Fig 12. Install bearing, washer and 1st-3rd apply clutch with turbine shaft assembly. See Fig 13. Install thrust shims on 1st-3rd apply clutch housing. Install reverse apply clutch and support tube. See Fig 14.
    NOTE: Turbine shaft end play was measured before disassembly. If end play is okay, use original thrust shims. If end play is not okay or new parts are installed, calculate difference and install required thrust shims.
  8. For checking purposes, install oil pump gasket and oil pump. See Figure. Position dial indicator and Support (VW 387) on transaxle case. See Fig 15.
  9. Press dial indicator on turbine shaft, and apply .040" (1.0 mm) preload. Move turbine shaft up and down. Turbine shaft end play should be .019-.047" (.50-1.20 mm).
  10. If end play is okay, go to next step. If end play is not okay, install required thrust shims. Thrust shims are available in thicknesses ranging from .04" (1.0 mm) to .07" (1.8 mm) in .008" (.20 mm) increments. Recheck turbine shaft end play.
  11. Remove oil pump and oil pump gasket. Install support tube and .12" (3.0 mm) thick outer splined plate for reverse apply clutch. Ensure groove on support tube engages wedge of one-way clutch. See Figure and Fig 14 .
  12. Install friction plates and outer splined plates for reverse apply clutch into transaxle case. See Fig 16. Install 3 springs and cap springs. Install the 2nd-4th brake clutch plates. Refer to specifications. See BRAKE CLUTCH PLATE APPLICATIONS  table. Also, see Fig 17. Install 3 spring caps to springs.
    Fig 12: Installing 3rd-4th Apply Clutch & Impeller Shaft
    G93H22506Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 13: Installing 1st-3rd Apply Clutch & Turbine Shaft
    G93I22507Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 14: Installing Support Tube
    G93J22508Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 15: Checking Turbine Shaft End Play
    G93J22409Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 16: Installing 2nd-4th Brake Clutch Plate & Springs
    G93D22411Courtesy of VOLKSWAGEN UNITED STATES, INC.
  13. Do not install top outer splined clutch plate or waved spring washer. Determine clearance of 2nd-4th brake clutch. Press 2nd-4th brake clutch assembly down. Using a depth gauge, measure distance from top of oil pump flange to 2nd-4th brake clutch (inner splined). See Fig 18.
  14. Place a straightedge across top of piston. Place gasket on oil pump flange. Using depth gauge, measure distance from straightedge to oil pump flange gasket. See Fig 19. Subtract thickness of straightedge.
  15. Subtract distance measured in step  13 from distance calculated in step  14. This gives 2nd-4th brake clutch-to-piston distance.
  16. Subtract .14" (3.6 mm) from value calculated in step  15. This determines thickness of last outer splined 2nd-4th brake clutch plate. Outer splined 2nd-4th brake clutch plates are available in thickness ranging from .080-.148" (2.00-3.75 mm), in .010" (.25 mm) increments.
    NOTE: Factory uses .14" (3.6 mm) value to allow for waved spring washer being installed with 2nd-4th brake clutch plates.
  17. Install 3 spring caps and last outer 2nd-4th brake clutch plate. Install waved spring washer. Install oil pump gasket. Install "O" ring to oil pump, and install oil pump. Install cover for transfer gears.
  18. Move gear change shaft to "P" position. Push manual valve operating lever with manual valve into valve body. Tighten set screw. Install sealing plug. See Figure. Install valve body. Install oil filter screen and oil pan. See Figure, Figure, Fig 20 and Fig 21 . Install torque converter.
Fig 17: Installing 2nd-4th Clutch Plates
G93A22509Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 18: Measuring Oil Pump Flange-To-Clutch Plate
G93D22510Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 19: Measuring Height Of Piston
G93E22511Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 20: Installing Manual Valve Operating Lever (097 Shown; 096 Is Similar)
G93F22512Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 21: Installing Valve Body
G95F19294Courtesy of VOLKSWAGEN UNITED STATES, INC.
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