General Repair Instructions

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when repairing the vehicle.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the service information, are summarized here. They apply to this service information.

Special tools and workshop equipment required

A list of the special tools used in the service information precedes each repair procedure.

Transmission 

When an automatic transmission is replaced, the VW ATF in the planetary gearbox, ATF LEVEL, CHECKING , and the gear oil in the final drive, FINAL DRIVE, CHECKING OIL LEVEL , must be checked and topped off as necessary. Capacities and specifications CAPACITIES .

• For transmission repairs, an exchange component is available for the shift elements, which is often more cost effective.
  Fig 1: Exploded View Of Transmission Shift Elements

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• When installing a transmission, make sure that the dowel sleeves are installed correctly.

Gaskets, oil seals 

• Radial shaft seals: Pack space between sealing lips with grease before installing.
  Fig 2: Identifying Oil Seals Sealing Lips

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• Always install new O-rings.
• After installing, check ATF level in planetary gearbox or gear oil in final drive, adjust to correct level if necessary.

Locking elements 

• Do not overstretch circlips; replace if necessary.
• Circlips must be properly seated in the grooves.
• Replace spring pins. Installation position: Slot must be longitudinal to line of force.
  Fig 3: Identifying Spring Pins

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Shims 

• Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
• Check for signs of burr and damage. Install only shims which are in perfect condition.

Bearings 

• Tapered roller bearings are allocated according to the transmission build date and code letters.
• Always replace tapered roller bearings which are mounted on a shaft together and use bearings from a single manufacturer.
• Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.
• Heat the inner races of tapered roller bearings to approx. 100°C before installing.
• Do not interchange the inner and outer races of same size bearings.

Nuts, bolts 

• Nuts and bolts for attaching covers and housings must be loosened and tightened in a crosswise pattern.
  Fig 4: Identifying Nut And Bolt

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• Do not distort particularly sensitive parts, e.g. valve body, and loosen or tighten diagonally in stages.
• The tightening torques stated apply to unoiled nuts and bolts.
• Threads of bolts that are secured by locking fluid are to be cleaned with a wire brush. Then insert bolts with AMV 185 100 A1.
• Always replace self-locking nuts.

Inner plates 

• Place new inner plates in ATF fluid for 15 minutes before installing.
  Fig 5: Placing New Inner Plates In ATF Fluid

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Valve body 

• Replace the valve body if any of the selector elements are scorched.

Clutches 

• Clutches K1, K2 and K3 should be disassembled only for cleaning. If parts are faulty, replace the clutch. Allocate clutches according to transmission code letters.

On Board Diagnostic (OBD) 

• Before repair work on the automatic transmission, the cause of the malfunction should be determined as precisely as possible with the aid of On Board Diagnostic (OBD). Refer to: Diagnostic Guide and refer to Diagnosis and Testing
  Fig 6: Identifying VAS 5051

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.