General Repair Notes

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

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

Transmission 

• Rules of cleanliness for working on automatic transmissions → Rules of cleanliness for working on automatic transmissions .

Fig 1: Securing Torque Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• On removed transmission, support torque converter against falling down with Bracket 30-211 A.
• Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
• After repair work on the transmission, clean ATF lines and ATF cooler, replace ATF filter.
• Check the following fluid levels after installing, top off if necessary. ATF in planetary gear → 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING , axle oil for front final drive → 39 - FINAL DRIVE, DIFFERENTIAL , axle oil in transfer case → 39 - FINAL DRIVE, DIFFERENTIAL . Install driveshaft → 00 - GENERAL, TECHNICAL DATA .

Impurities in ATF area 

If ATF area is very soiled caused by worn friction linings:

• Disassemble transmission completely and clean, replace ATF oil tubes.
• Disassemble and check all clutches.
• Replace torque converter (cannot be cleaned).
• Replace valve body (cannot be cleaned).

• Clean ATF lines and ATF cooler, replace ATF filter.

O-rings, gaskets, shaft seals and seals. 

• Always replace O-rings, gaskets, shaft seals and seals.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• The open side of the shaft seals point toward the fluid to be sealed in.
• To install, thinly coat shaft seals along outer circumference and on sealing lip with ATF.

• Lightly lubricate O-rings with ATF or Vaseline before installing, this prevents the rings from being pinched when inserting.
• Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.

Bolts and nuts 

• Loosen bolts in reverse order of tightening.
• Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
• The tightening torques stated apply to unoiled bolts and nuts.
• Replace self-locking bolts and nuts.

Locking elements 

• Do not over-stretch circlips.
• Always replace circlips which have been damaged or over-tensioned.
• Circlips must be properly seated in the base of the groove.

Fig 2: Identifying Spring Pins Installation Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace spring pins. Installation position: Slit is longitudinal to direction of force - arrow  -.

Bearings 

• Slightly grease mount with ATF before inserting.
• Attach mount and adjustment shims only with Vaseline. Other lubricants cause malfunctions of the hydraulic transmission controls.

Oil tubes 

• Once removed, oil tubes must always be replaced.
• If transmission is very dirty, oil tubes must be replaced.