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Volkswagen Passat 1995, Official Factory Repair Manual

The Official Factory Repair Manual for the 1995 Volkswagen Passat is a comprehensive guide for vehicle owners and enthusiasts. This manual contains detailed instructions and diagrams to assist in the maintenance and repair of the Passat. It is available for free download from manualshive.com, ensuring easy access to this invaluable resource.

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01-18

 

    

Location: The Kickdown Switch (arrow) is integrated 
with the Accelerator Pedal cable and is located on the 
bulkhead in the engine compartment.  

Removing and installing Kickdown Switch 

 

 

Repair Manual, General, Engine, Repair Group 20

 

  

Fig. 10  Kickdown Switch -F8-

 

-  Disconnect Accelerator Pedal cable to remove and 

install Kickdown Switch, then reinstall cable and 
adjust. 

    

Location: The Brake Light Switch (arrow) is located 
on the pedal cluster.  

Removing and installing Brake Light Switch 

 

 

Repair Manual, Suspension, Wheels, Brakes, 

Steering, Repair Group 47

   

Fig. 11  Brake Light Switch -F-

 

Page 18 of 19

On Board Diagnostic (OBD), general information

12/6/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.AT02.01.1

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ProCarManuals.com

Summary of Contents for Passat 1995

Page 1: ...WWW ALL TRANS BY ProCarManuals com ...

Page 2: ...WWW ALL TRANS BY ProCarManuals com ...

Page 3: ... functions Diagnostic Trouble Code DTC Memory checking Diagnostic Trouble Code DTC table Diagnostic Trouble Code DTC Memory erasing Basic setting initiating Reading measured value block Transmission electrical testing Electrical testing on Transmission Control Module TCM with 38 pin connector Test table Electrical testing on Transmission Control Module TCM with 68 pin connector Test table 32 Torqu...

Page 4: ...y overview I ATF pump to support tube removing and installing II Reverse gear clutch K2 to large sun gear removing and installing III Free wheel and reverse gear brake B1 removing and installing IV Planet carrier and input gear removing and installing Planetary gearbox disassembling and assembling Planetary gearbox adjustments overview Planet carrier adjusting Reverse gear brake B1 adjusting Clutc...

Page 5: ...drive checking Drive flange oil seal removing and installing Final drive disassembling and assembling Repair overview Input gear removing and installing Drive pinion removing and installing Differential removing and installing Differential disassembling and assembling Final drive adjusting Adjustment overview Adjustments to be completed after replacing individual components Drive pinion adjusting ...

Page 6: ...nder engine Applications page 00 3 The transmission is identified by type 096 code letters and date of manufacture Location on transmission Code letters arrow 1 Automatic transmission 096 arrow 2 Automatic transmission 096 2 Page 1 of 2 Transmission identification 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 00 1 WWW ALL TRANS BY ProCarManuals...

Page 7: ...listed on the vehicle data plates Example CFF 03 01 4 I I I I I I I I Transmission code letters Day Month Year Date e g 3 Jan 1994 Page 2 of 2 Transmission identification 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 00 1 WWW ALL TRANS BY ProCarManuals com ...

Page 8: ... 93 10 93 Number of plates Inner Outer Inner Outer Inner Outer Clutch K1 5 5 5 5 Clutch K2 5 5 5 5 Clutch K3 6 5 5 4 Brake B1 5 5 5 5 Brake B2 6 7 6 7 Application Model Passat 1995 Passat 1995 Engine 2 8 liter 128 kW 172 hp 2 0 ltr 85 kW 115 hp Page 1 of 2 Code letters model engine applications ratios equipment 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair i...

Page 9: ...gear 61 61 Ratio 0 984 0 984 Final drive No of teeth Drive pinion 20 18 Final drive gear 74 76 Ratio 3 700 1 4 222 1 Drive shaft Flange diameter mm 100 star shape ATF cooler Equipment Pressure side 6 row Pressure side 6 row Page 2 of 2 Code letters model engine applications ratios equipment 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 00 2 WWW...

Page 10: ...smission Initial filling 0 75 liter 0 79 US qt 096 Oil change Filled for life No change Lubricant Gear oil SAE75 W90 synthetic oil Note Gear oil SAE 75 W90 synthetic oil is available as follows 0 5 liter container Part No G 052 145 A1 1 0 liter container Part No G 052 145 A2 Page 1 of 1 Capacities 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 0...

Page 11: ...e ATF in the planetary transmission page 37 43 and the gear oil in the final drive page 39 1 is to be checked and topped up as necessary ATF and oil capacities and specifications page 00 5 When installing the transmission make sure that the dowel sleeves for engine transmission alignment are installed correctly Gaskets oil seals Always install new O rings Radial shaft seals Pack space between seal...

Page 12: ... to be cleaned with a wire brush Then insert bolts with AMV 185 100 A1 Always replace self locking nuts Bearings Install needle bearings with the inscribed side thicker sheet metal facing the drift Lubricate all bearings in transmission with gear oil before installing Oil with special care for measuring friction torque Heat the inner races of tapered roller bearings to approx 100 C 212 F before in...

Page 13: ...haft always replace them together and use bearings from the same manufacturer Page 3 of 4 Repair instructions 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 00 4 WWW ALL TRANS BY ProCarManuals com ...

Page 14: ... Clutches Clutches K1 K2 and K3 should initially be dismantled only for cleaning If parts are malfunctioning replace clutch Clutch applications are determined by the transmission code letters On Board Diagnostic OBD program Before carrying out any automatic transmission repairs first determine the cause of the malfunction as precisely as possible with the aid of the On Board Diagnostic capability ...

Page 15: ...malfunction or an open circuit the cause of the malfunction can be determined quickly Malfunctions in the monitored sensors or components are stored in DTC Memory along with an indication of the type of malfunction Malfunctions that occur only occasionally are defined as sporadic malfunctions and are coded as such The Transmission Control Module TCM J217 analyzes the information and distinguishes ...

Page 16: ...3 or 2 the 3rd gear emergency running mode is activated If a malfunction occurs while the selector lever is in position 1 P N or R the emergency running mode for that stage is activated If the engine is started again in the emergency running mode and the malfunction occurs when the selector lever is in position D 3 or 2 then 3rd gear is activated hydraulically until the malfunction is repaired If ...

Page 17: ...ns that are stored in DTC Memory as sporadic malfunctions will be displayed as such when retrieved by the VAG 1551 Scan Tool ST In such cases the letters SP appear on the right side of the Scan Tool display If the printer is switched on sporadic DTC is printed out after the malfunction is addressed Malfunctions that are stored in DTC Memory as sporadic malfunctions are automatically erased after 1...

Page 18: ...de DTM no Basic setting yes Transmission Control Module TCM coding no Reading measured value block VAG 1551 function 08 yes Component locations page 01 7 Page 4 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 19: ... Memory function 02 No DTC recognized Identification NOT OK Correct malfunction according to DTC table End Replace control module Read measured value block 08 Replace component Transmission Perform electrical tests Results as specified Results not as specified A B C D Page 5 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto ...

Page 20: ...e component Initiate basic setting function 04 Carry out road test and Check DTC Memory again function 02 If No DTC recognized is indicated on display the On Board Diagnostic program has been completed Page 6 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 21: ...J217 Location removing and installing Fig 1 Removing with 68 pin connector Fig 2 Installing with 68 pin connector Fig 3 Checked by On Board Diagnostic OBD program VAG 1551 Scan Tool ST connecting and selecting functions page 01 20 2 Engine Control Module ECM Location Fig 13 Removing and installing Page 7 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com v...

Page 22: ...lves N88 N89 N90 N91 N92 N93 N94 and the Transmission Fluid Temperature Sensor G93 are attached to the valve body Components checked by On Board Diagnostic OBD program Page 8 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 23: ...ic OBD program 6 Vehicle Speed Sensor VSS G68 Location removing and installing Fig 6 Checked by On Board Diagnostic OBD program Page 9 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 24: ...gnal is directed to Transmission Control Module TCM via Engine Control Module ECM Signal can only be checked by reading measured value block page 01 40 If a malfunction is indicated then also carry out On Board Diagnostic OBD checks of Engine Control Module ECM After repairs initiate basic settings Basic setting initiating page 01 39 Page 10 of 19 On Board Diagnostic OBD general information 12 6 2...

Page 25: ...nd installing Can be checked by reading measured value block page 01 40 10 Kick Down Switch F8 Location Fig 10 Removing and installing remove and install Accelerator Pedal cable then adjust afterward Accelerator Pedal cable adjusting Can be checked electrically page 01 59 and via reading measured value block page 01 40 Page 11 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn ...

Page 26: ...n be checked electrically page 01 59 and via reading measured value block page 01 40 12 Park Neutral Position PNP Relay J226 Location Fig 12 Page 12 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 27: ...ransmission Control Module TCM J217 Fold up rear seat Release multi pin connector lock by pressing off clip then disconnect multi pin connector Remove TCM Install in reverse order of removal Page 13 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 28: ...nsmission Control Module J217 TCM with 68 pin connector installing Place multi pin connector in position on control module locating pins arrows then lock multi pin connector Page 14 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 29: ... on rear of the transmission Removing and installing Multi function TR Switch Fig 5 Multi function Transmission Range TR Switch F125 Disconnect harness connector from Multi function Transmission Range TR Switch Remove bolt and retainer then remove switch Replace seal Install in reverse order of removal Retainer bolt tightening torque 10 Nm 7 ft lb Page 15 of 19 On Board Diagnostic OBD general info...

Page 30: ...or is located on the throttle valve housing engine Component design may vary depending on the engine application Removing and installing Throttle Position TP Sensor Removal and installation are described in the appropriate fuel injection and ignition booklet Check engine code Repair Manual Fuel Injection Ignition Repair Group 24 Fig 7 Throttle Position TP Sensor G69 Page 16 of 19 On Board Diagnost...

Page 31: ...ontrol Switch is located on the steering column switch Removing and installing Cruise Control Switch Repair Manual Electrical Equipment Repair Group 94 Fig 9 Cruise Control Switch E45 Page 17 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals com ...

Page 32: ...dal cable to remove and install Kickdown Switch then reinstall cable and adjust Location The Brake Light Switch arrow is located on the pedal cluster Removing and installing Brake Light Switch Repair Manual Suspension Wheels Brakes Steering Repair Group 47 Fig 11 Brake Light Switch F Page 18 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Dis...

Page 33: ...ontrol Module ECM is located in the heating ventilation intake plenum chamber right side Removing and installing ECM Repair Manual Fuel Injection Ignition Repair Group 24 Fig 13 Engine Control Module ECM Page 19 of 19 On Board Diagnostic OBD general information 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 1 WWW ALL TRANS BY ProCarManuals co...

Page 34: ...n left next to relay panel Check Battery Ground GND strap and Ground GND strap between Battery and transmission Selector lever in position P and handbrake applied Remove Data Link Connector DLC cover on right side of instrument cluster With ignition switched OFF connect VAG 1551 Scan Tool ST with VAG 1551 3 adapter cable Page 1 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypubl...

Page 35: ...0 can be carried out in the Rapid data transfer operating mode Then all vehicle control units will be interrogated automatically Switch ignition ON Switch printer on with the PRINT button indicator lamp in button lights up Press button 1 for Rapid data transfer operating mode Rapid data transfer HELP Enter address word XX Indicated on display Press buttons 0 and 2 enter address word 02 for Transmi...

Page 36: ...mission Control Module TCM can indicate an identification number different from that shown in the example Control Module applications Parts catalog microfiche 096 927 731 AD Part number AG4 Gearbox 096 4 speed automatic transmission 096 1283 EPROM Program level Coding 00000 Not required at present WSC 131071 Dealership number of the VAG 1551 Scan Tool ST with which the most recent coding was carri...

Page 37: ...ission Control Module TCM Electrical Wiring Diagrams Troubleshooting and Component Locations binder Diagnostic Trouble Code DTC table under DTC 65535 for control module malfunctioning page 01 26 Perform electrical test step 1 page 01 59 Check wiring connections to Data Link Connector DLC sockets Press button Rapid data transfer HELP Select function XX Indicated on display After pressing the HELP b...

Page 38: ...ue block Page 01 40 Further functions which can be printed out by pressing the HELP button need not be considered After checking and completing a function the VAG 1551 Scan Tool ST returns to the following start condition Rapid data transfer HELP Select function XX Indicated on display Page 5 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action...

Page 39: ...tic Trouble Codes DTC or No DTC recognized appears in the display Stored malfunctions are displayed in turn and printed out After the last malfunction has been displayed and printed out the malfunctions should be corrected as described in the Diagnostic Trouble Code DTC table page 01 26 Press button Press button Rapid data transfer HELP Select function XX Indicated on display Note After checking D...

Page 40: ...ns are detected when checking Diagnostic Trouble Code DTC Memory also test the wiring to the components for short circuits and open circuits according to the wiring diagram Electrical Wiring Diagrams Troubleshooting and Component Locations binder The DTCs are printed out in the Rapid data transfer mode only when the VAG 1551 Scan Tool printer is switched ON Example Diagnostic Trouble Code 5 digit ...

Page 41: ...al tests from page 01 59 00262 Open circuit or short to Ground GND Check wiring and connections according to wiring diagram 2 Solenoid Valve 3 N90 Solenoid Valve 3 N90 malfunctioning Read measured value block page 01 40 display group number 04 Open circuit1 Short to Ground GND 1 Carry out electrical tests from page 01 59 1 One of these displays appears in addition to the relevant component 2 First...

Page 42: ...al tests from page 01 59 00268 Open circuit or short to Ground GND Check wiring and connections according to wiring diagram 2 Solenoid Valve 6 N93 Solenoid Valve 6 N93 malfunctioning Read measured value block page 01 40 display group number 02 Open circuit1 Short to Ground GND 1 Carry out electrical tests from page 01 59 1 One of these displays appears in addition to the relevant component 2 First...

Page 43: ...red value block page 01 40 display group number 02 Carry out electrical tests from page 01 59 Replace Vehicle Speed Sensor VSS G68 page 01 16 32 No signal Input gear impulse wheel loose Replace input gear page 39 8 1 One of these displays appears in addition to the relevant component 2 First check connections for contact corrosion or water contamination and replace if necessary When the display in...

Page 44: ...mperature Sensor G93 malfunctioning Read measured value block page 01 40 display group number 05 No malfunction identified Carry out electrical tests from page 01 59 1 A malfunctioning Transmission Fluid Temperature Sensor is indicated 2 First check connections for contact corrosion or water contamination and replace if necessary When the display indicates solenoid malfunctions especially check th...

Page 45: ...s from page 01 59 Replace Throttle Position TP Sensor G69 Bring system to basic settings page 01 39 Signal outside tolerances On vehicles with 6 cylinder engine from 01 93 Motronic Engine Control Module ECM malfunctioning signal from the Throttle Position TP Sensor G69 is routed to Transmission Control Module TCM J217 via ECM Repair Manual 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Vehi...

Page 46: ...3 Check Engine Control Module 00532 Battery malfunctioning Test Battery Positive Voltage B Repair Manual Electrical Equipment Repair Group 27 Supply Voltage B Insufficient system voltage Read measured value block page 01 40 display group number 02 Test voltage supply to Transmission Control Module J217 Carry out electrical tests page 01 59 Page 13 of 43 On Board Diagnostic OBD program 12 6 2004 ht...

Page 47: ...Engine Control Module Open circuit1 Short to Ground GND 1 Bring system to basic settings page 01 39 00596 10 pin connector between valve body conductor strip and wiring loom Check wiring and connections according to wiring diagram Short circuit between solenoid valve lines Conductor strip to valve body defective Carry out electrical tests from page 01 59 Replace valve body page 38 22 1 One of thes...

Page 48: ...heck Engine Control Module replace if necessary No signal Bring system to basic settings page 01 39 00641 Transmission becomes too hot max 148 C 298 F If ATF temperature is too high transmission shifts down into next lower gear Check ATF level page 37 43 Read measured value block page 01 40 display group number 05 read transmission fluid temperature Transmission fluid temperature Trailer load of v...

Page 49: ...tle Position TP Sensor G69 malfunctioning Carry out repairs for Throttle Position TP Sensor G69 described under Repairing malfunction DTC 00518 Incorrect signal Kick Down Switch F8 malfunctioning Repair Manual 2 0 Liter 1 8 Liter or 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Read measured value block page 01 40 display group number 01 Carry out electrical tests from page 01 59 Adjust Ac...

Page 50: ...Control Module TCM J217 should NOT be replaced and brought into the basic setting page 01 39 until the cause of the malfunction has been determined and the following malfunctions have been corrected Mechanical malfunctions Hydraulic malfunctions All affected electrical components and cable connections Page 17 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servl...

Page 51: ...ess Q button to confirm input Attention DTC Memory is not interrogated Indicated on display Note If the ignition was switched OFF between checking and erasing the DTC Memory for example then the DTC Memory will not be erased Adhere strictly to the sequence of operations i e always check DTC Memory first before attempting to erase Page 18 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn b...

Page 52: ... out with printer switched on Transmission Control Module TCM J217 given too little time to recognize malfunctions When the DTC Memory is interrogated the following message should be displayed Wait about 1 minute before checking DTC Memory again After checking and erasing DTC Memory carry out a test drive and checking DTC Memory again No DTC recognized Page 19 of 43 On Board Diagnostic OBD program...

Page 53: ...ch Replacing Transmission Control Module TCM J217 Connect VAG 1551 Scan Tool ST enter address word 02 for Transmission Electronics and advance Scan Tool program until Select function XX appears in the display page 01 20 Rapid data transfer HELP Select function XX Indicated on display Note Accelerator Pedal must remain in Closed Throttle Position Press buttons 0 and 4 to select function 04 Basic se...

Page 54: ...ds Press button Rapid data transfer HELP Select function XX Indicated on display Reading measured value block Connect VAG 1551 Scan Tool ST enter address word 02 for Transmission Electronics and advance Scan Tool program until Select function XX is indicated on display from page 01 20 Rapid data transfer HELP Select function XX Indicated on display Press buttons 0 and 8 to select function 08 Read ...

Page 55: ...s Q button to confirm input Reading measured value block 1 1 2 3 4 Indicated on display There are always 4 display fields in the measured value block displayed in physical units if necessary Key to interpreting individual values in display fields 1 through 4 Test table page 01 44 Page 22 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto...

Page 56: ... voltage Accelerator Pedal value Switch positions 02 1 2 3 4 Actual Solenoid Valve 6 N93 voltage Specified Solenoid Valve 6 N93 voltage Battery Positive Voltage B Voltage at Vehicle Speed Sensor VSS G68 03 1 2 3 4 Vehicle speed Engine speed Gear selected Accelerator Pedal value 04 1 2 Solenoid valves Gear selected Page 23 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers...

Page 57: ...nsmission fluid ATF temperature Switch output Gear to select Engine speed Page 24 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 58: ...n the log If the values in all the display fields are as specified Press button Rapid data transfer HELP Select function XX Indicated on display Page 25 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 59: ...smission Range TR Switch F125 Stationary P P Check Multi Function Transmission Range TR Switch F125 Carry out electrical tests from page 01 59 Selector R R lever N N in D D 3 3 2 2 cont d 1 1 Page 26 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 60: ...n or 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Vehicles from 01 93 with 6 cylinder engine carry out On Board Diagnostic OBD program for Engine Control Module ECM Check Throttle Position TP Sensor G69 Carry out electrical tests from page 01 59 Adjusting or replacing Throttle Position TP Sensor G69 Bring system into basic settings page 01 39 Wide Open Throttle min max 3 5 V 4 680 V Page ...

Page 61: ...ic Engine Coolant Temperature ECT min 80 C 176 F Page 28 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 62: ...ight Switch F Carry out electrical tests from page 01 59 Not operated 0 Traction control system 2 Activated 1 Not applicable for vehicles covered by this manual Not activated 0 Electronic program switch Electronic program switch is integrated in control unit and activates the E or S program automatically 3 S selected 1 cont d cont d E selected 0 1 Engine with Mono Motronic Engine Coolant Temperatu...

Page 63: ...s mission Range TR Switch F125 5 Selector lever in R N D 3 2 1 Check Multi Function Transmission Range TR Switch F125 Carry out electrical tests from page 01 59 P 1 0 6 Selector lever in P R 2 1 1 N D 3 0 7 Selector lever in P R N D 1 3 2 1 0 8 Selector lever in P R N 1 D 3 2 1 0 Page 30 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto...

Page 64: ...ve Voltage B Stationary min 10 8 V Check Battery replace if necessary Check voltage supply to Transmission Control Module J217 Carry out electrical tests from page 01 59 Replace Transmission Control Module J217 page 01 7 Bring system into basic settings page 01 39 max 16 0 V 4 Vehicle Speed Sensor G68 Stationary min 2 20 V Check Vehicle Speed Sensor G68 Carry out electrical tests from page 01 59 m...

Page 65: ...on or 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Tune engine if necessary 3 Gear selected Driving1 Neutral 0 Check Solenoid Valves Carry out electrical tests from page 01 59 Reverse R 1 hydraulic 1 2 hydraulic 2 3 hydraulic 3H cont d 4 mechanical 4 1 While driving with drive gear selected a second technician is needed for reading the specified values Page 32 of 43 On Board Diagnostic OB...

Page 66: ...n Throttle percent value increases constantly Bring system into basic settings Page 01 39 Wide Open Throttle 99 100 1 While driving with drive gear selected a second technician is needed for reading the specified values Page 33 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManual...

Page 67: ...ry valves that affect gear selection changes and are only controlled during gear changes They are displayed in positions 5 and 6 VAG 1551 Scan Tool display field 1 is made up of 6 characters 0000 00 and is read as follows Display on VAG 1551 Scan Tool ST Display field 1 Display 1 Display 2 Display 3 Display 4 Display 5 Display 6 N88 N89 N90 N91 N92 N94 Non activated Solenoid Valves are displayed b...

Page 68: ...ion 5 N94 position 6 P 1 0 0 1 00 Solenoid Valves are selected according to driving conditions electrical tests from page 01 59 Check Solenoid Valves R1 0 0 0 0 00 N 1 0 0 1 00 D1 1 0 0 0 1 00 2 0 1 0 1 00 3H 0 0 0 0 00 4 1 1 1 1 00 31 1 0 0 0 1 00 2 0 1 0 1 00 3H 0 0 0 0 00 21 1 0 0 0 1 00 2 0 1 0 1 00 Page 35 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw ser...

Page 69: ...cted a second technician is needed for reading the specified values Page 36 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 70: ...9 Check Solenoid Valves Reverse R 1 hydraulic 1 2 hydraulic 2 3 hydraulic 3H cont d 4 mechanical 4 1 While driving with drive gear selected a second technician is needed for reading the specified values Page 37 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 71: ... R R N N D D 3 3 2 2 1 1 4 Vehicle speed Speed at which vehicle is driven 1 km h The Speedometer reading and VAG 1551 Scan Tool ST display may differ slightly 1 While driving with drive gear selected a second technician is needed for reading the specified values Page 38 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW...

Page 72: ...ent Repair Manual 2 0 Liter Fuel Injection Ignition 1 8 Liter Fuel Injection Ignition or 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Check wiring according to wiring diagram Replace Engine Control Module ECM Replace Transmission Control Module TCM J217 page 01 7 Bring system into basic settings page 01 39 Display 1 is switched on 1 is switched off 0 2 switched on 1 cont d cont d switched...

Page 73: ...econd technician is needed for reading the specified values Page 40 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCarManuals com ...

Page 74: ... N110 Display 3 is switched on 1 is switched off 0 4 switched on 1 switched off 0 Cruise control Check wiring according to wiring diagram 5 switched on 1 Electrical Wiring Diagrams Troubleshooting and Component Locations binder Check cruise control cont d cont d switched off 0 Page 41 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto ty...

Page 75: ...diagram was not switched off 0 Repair Manual Heating and Air Conditioning Repair Group 87 Check air conditioner 7 Park Neutral signal Selector lever in Check routing of wiring according to wiring diagram P N 1 cont d 1 2 3 D 0 Page 42 of 43 On Board Diagnostic OBD program 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 2 WWW ALL TRANS BY ProCa...

Page 76: ...ission Control Module TCM J217 page 01 7 4 mechanical 4 4 Engine Speed RPM Driving 1 with engine running RPM Repair Manual 2 0 Liter Fuel Injection Ignition 1 8 Liter Fuel Injection Ignition or 2 8 Liter VR6 Fuel Injection Ignition Repair Group 24 Tune engine if necessary 1 While driving with drive gear selected a second technician is needed for reading the specified values Page 43 of 43 On Board ...

Page 77: ...tact repair if necessary Check Battery Ground GND strap as well as Ground GND strap between Battery and transmission CAUTION To avoid damaging the electronic components select the appropriate function and measurement range on the test equipment before connecting the test leads Page 1 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto typ...

Page 78: ...m the specified values clean the sockets and connectors of the test equipment and test leads then repeat the test Before replacing a particular component test the wiring and connections and particularly if specified values are below 10 ohms 10 repeat the resistance measurement Electrical testing on Transmission Control Module with 38 pin connector page 01 61 Electrical testing on Transmission Cont...

Page 79: ... ignition OFF Disconnect multi pin connector from Transmission Control Module TCM J217 Connect VAG 1598 test box to multi pin connector using VAG 1598 9 adapter Resistance measurements VAG 1598 9 adapter disconnected from TCM Voltage measurements VAG 1598 9 adapter connected to TCM arrows Page 3 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display act...

Page 80: ...n TP Sensor G69 1 29 Throttle Position TP Sensor G69 Ground GND 1 11 Not assigned 30 Transmission fluid ATF temperature 12 Selector lever display or not assigned 31 Not assigned 13 Vehicle Speed Sensor VSS G68 screening 32 Vehicle Speed Sensor VSS G68 14 Not assigned 33 Vehicle Speed Sensor VSS G68 15 Multi Function Transmission Range TR Switch F125 34 Multi Function Transmission Range TR Switch F...

Page 81: ...ylinder engine Throttle Position TP Sensor signal terminal 9 is routed to the Transmission Control Module TCM via the Motronic Engine Control Module ECM Page 5 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 82: ...ut test step 3 Solenoid Valve 7 N94 Carry out test step 12 Brake Light Switch F Carry out test step 4 Kick Down Switch F8 Carry out test step 14 Multi Function Transmission Range TR Switch F125 Carry out test step 5 Vehicle Speed Sensor G68 Carry out test step 15 Solenoid Valve 1 N88 Carry out test step 6 Transmission Fluid Temperature Sensor G93 Carry out test step 16 Solenoid Valve 2 N89 Carry o...

Page 83: ...sion Control Module TCM J217 Ignition switched ON approx Battery Positive Voltage B Check wiring according to wiring diagram Check wiring from pin 1 to Ground GND Check wiring from pin19 to terminal 15 central electrics Page 7 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals...

Page 84: ...29 Ignition switched ON When accelerating from idle to full throttle voltage level increases constantly Repair Manual 2 0 Liter Fuel Injection Ignition or 1 8 Liter Fuel Injection Ignition Repair Group 24 Check Throttle Position TP Sensor replace if necessary Bring system into basic setting page 01 39 Idling min Idling max 0 156 V 0 8 V Wide Open Throttle min max 3 5 V 4 68 V 1 Engine with Mono Mo...

Page 85: ...ECM and can only be measured by the Reading measured value block function using the VAG 1551 Scan Tool page 01 40 Page 9 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 86: ...stem into basic setting page 01 39 With brake operated 0 V Carry out test step 4 if necessary replace Transmission Control Module TCM J217 page 01 7 Bring system into basic setting page 01 39 4 26 1 Brake Light Switch F Ignition switched ON Brake pedal not depressed 0 V Check wiring according to wiring diagram Replace Brake Light Switch F Brake pedal depressed approx Battery Positive Voltage B Pag...

Page 87: ... Function TR Switch F125 page 01 15 Fig 5 Selector lever positions R N D 3 and 2 Selector lever positions P and 1 0 to 0 8 V 15 1 Selector lever positions P R 2 and 1 4 5 to 5 V Selector lever positions N D and 3 0 to 0 8 V 35 1 Selector lever positions P R N and D 4 5 to 5 V Selector lever positions 3 2 and 1 0 to 0 8 V 16 1 Selector lever positions P R and N approx Battery Positive Voltage B Pag...

Page 88: ...positions D 3 2 and 1 0 to 0 8 V Page 12 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 89: ...iring diagram 23 1 TCM J217 disconnected infinite 1 Replace valve body page 38 22 8 3 18 Solenoid Valve 3 N90 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram 3 1 TCM J217 disconnected infinite 1 Replace valve body page 38 22 9 2 18 Solenoid Valve 4 N91 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram 2 1 TCM J217 disconnected inf...

Page 90: ...lenoid Valve 6 N93 Ignition switched OFF 4 5 to 6 5 Check routing of wiring according to wiring diagram Replace valve body page 38 22 25 1 TCM J217 disconnected infinite 1 12 21 18 Solenoid Valve 7 N94 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram Replace valve body page 38 22 21 1 TCM J217 disconnected infinite 1 1 Switch multimeter to largest Ohms range Page ...

Page 91: ...tched OFF Transmission Control Module TCM J217 disconnected Accelerator Pedal NOT depressed infinite 1 Repair Manual 2 0 Liter General Engine 1 8 Liter General Engine or 2 8 Liter VR6 General Engine Repair Group 20 Check routing of wiring according to wiring diagram Adjust Accelerator Pedal cable or replace Depress Accelerator Pedal pressed down as far as kickdown less than 1 5 1 Switch multimeter...

Page 92: ...nsor VSS G68 Ignition switched OFF Transmission Control Module TCM J217 disconnected Check wiring according to wiring diagram Replace Vehicle Speed Sensor VSS G68 page 01 16 Fig 6 min 0 8 K max 0 9 K Page 16 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 93: ...dule TCM J217 disconnected Check wiring according to wiring diagram Replace valve body page 38 22 Transmission fluid ATF temperature approx 20 C 68 F 0 247 M Switch to 200 K measuring range Transmission fluid ATF temperature approx 60 C 140 F approx 120 C 248 F 48 8 K 7 4 K Page 17 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type ...

Page 94: ... direction of arrow then disconnect from control module Wiring to and from the 68 pin TCM connector can be checked according to the wiring diagram using the VAG 1598 18 test box Connect VAG 1598 18 test box to multi pin connector 1 and lock moving in direction of arrow Page 18 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repai...

Page 95: ...uides arrows are engaged with the TCM pins Re connect multi pin connector to TCM and lock Page 19 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 96: ...ot assigned 9 Solenoid Valve 3 N90 27 Not assigned 10 Solenoid Valve 7 N94 28 Throttle Position Sensor G69 Ground GND 1 11 Park Neutral Position PNP signal 29 Shiftlock Solenoid N110 12 Kickdown for air conditioner 30 Not assigned 13 Ignition timing influence 31 Not assigned 14 Not assigned 32 Not assigned 15 Brake Light Switch F signal voltage 33 Not assigned 16 Kick Down Switch F8 34 Not assigne...

Page 97: ...ssion Control Module TCM via Motronic Engine Control Module ECM and can only be checked using the Reading measured value block function of the VAG 1551 Scan Tool ST page 01 40 Page 21 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 98: ...ction Transmission Range TR Switch F125 48 Not assigned 64 Engine Speed RPM Sensor G28 49 Not assigned 65 Vehicle Speed Sensor G68 Diesel engine 50 Throttle Position TP Sensor G69 5 volts 1 66 Not assigned 51 Not assigned 67 Solenoid Valves voltage supply 52 Not assigned 68 Not assigned 1 Signal contacts 5 and 28 and regulated voltage supply contact 50 not assigned on vehicles with 6 cylinder engi...

Page 99: ...t step 3 Solenoid Valve 7 N94 Carry out test step 12 Throttle Position TP Sensor G69 Carry out test step 4 Kick Down Switch F8 Carry out test step 14 Multi Function Transmission Range TR Switch F125 Carry out test step 5 Vehicle Speed Sensor G68 Carry out test step 15 Solenoid Valve 1 N88 Carry out test step 6 Transmission Fluid Temperature Sensor G93 Carry out test step 16 Solenoid Valve 2 N89 Ca...

Page 100: ...N110 Ignition switched ON Brake pedal NOT depressed approx Battery Positive Voltage B Shift mechanism servicing page 37 1 Check wiring according to wiring diagram Replace Shiftlock Solenoid N110 Depress brake pedal 0 2 V 3 15 1 Brake Light Switch F Ignition switched ON Brake pedal NOT depressed 0 V Repair Manual Suspension Wheels Brakes Steering Repair Group 47 Check wiring according to wiring dia...

Page 101: ...ositive Voltage B Page 25 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 102: ...n Ignition or 1 8 Liter Fuel Injection Ignition Repair Group 24 Check wiring according to wiring diagram Adjust Throttle Position TP Sensor and replace if necessary Bring system into basic setting page 01 39 Accelerator Pedal position Idling min max 0 7 K 1 8 K Wide Open Throttle min max 2 1 K 3 9 K 5 50 Throttle Position TP Sensor G69 1 Accelerator Pedal position Idling Page 26 of 33 Transmission...

Page 103: ... cylinder engine Signal from TP Sensor G69 is directed to TCM via ECM and can only be measured using the Reading measured value block function of the VAG 1551 Scan Tool page 01 40 Page 27 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 104: ...ssary Replace Multi Function TR Switch F125 page 01 15 31 Selector lever positions P and 1 0 8 to 1 40 1 Selector lever positions P R 2 and 1 infinite 1 Selector lever positions N D and 3 0 8 to 1 62 1 Selector lever positions P R N and D infinite 1 Selector lever positions 3 2 and 1 0 8 to 1 18 1 Switch to voltage measuring range 20 V Selector lever positions P R and N approx Battery Positive Vol...

Page 105: ...d 1 0 V 1 Switch multimeter to largest ohms range Page 29 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY ProCarManuals com ...

Page 106: ...ding to wiring diagram Replace valve body page 38 22 54 1 infinite 1 8 9 67 Solenoid Valve 3 N90 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram Replace valve body page 38 22 9 1 infinite 1 9 47 67 Solenoid Valve 4 N91 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram Replace valve body page 38 22 47 1 infinite 1 1 Switch multimet...

Page 107: ...diagram Replace valve body page 38 22 58 1 infinite 1 22 1 12 10 67 Solenoid Valve 7 N94 Ignition switched OFF 55 to 65 Check routing of wiring according to wiring diagram Replace valve body page 38 22 10 1 infinite 1 13 23 29 Shiftlock Solenoid N110 Ignition switched OFF 14 to 25 Shift mechanism servicing page 37 1 Check routing of wiring according to wiring diagram Replace Shiftlock Solenoid N11...

Page 108: ... Pedal cable or replace Depress Accelerator Pedal as far as kickdown less than 1 5 1 Switch multimeter to largest ohms range Switch to resistance measuring range 20 K Test step VAG 1598 18 sockets Test of Test conditions Additional operations Specified value Repairing malfunction 15 20 65 Vehicle Speed Sensor VSS G68 Ignition switched OFF Check wiring according to wiring diagram Replace Vehicle Sp...

Page 109: ...nition switched OFF Check wiring according to wiring diagram Replace valve body page 38 22 approx 20 C 68 F Transmission fluid ATF temperature 0 247 M Switch to 200 K measuring range approx 60 C 140 F approx 120 C 248 F 48 8 K 7 4 K Page 33 of 33 Transmission electrical testing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 01 3 WWW ALL TRANS BY...

Page 110: ...talling the torque converter make sure that both drive pins engage in the recesses in the ATF pump inner wheel Page 1 of 4 Torque converter 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 32 1 WWW ALL TRANS BY ProCarManuals com ...

Page 111: ...tters arrow Transmission torque converter applications tables starting page 00 3 Torque converter code letters Transmission installed Page 2 of 4 Torque converter 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 32 1 WWW ALL TRANS BY ProCarManuals com ...

Page 112: ...rhaul of the transmission drain the torque converter as follows Extract automatic transmission fluid ATF from torque converter using VAG 1358A with VAG 1358 A 1 probe or EZ1 fluid evacuator Page 3 of 4 Torque converter 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 32 1 WWW ALL TRANS BY ProCarManuals com ...

Page 113: ...ing torque converter oil seal Installing torque converter oil seal Drive in seal until flush Page 4 of 4 Torque converter 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 32 1 WWW ALL TRANS BY ProCarManuals com ...

Page 114: ...ched ON Brake pedal not depressed Selector lever is locked and cannot be shifted out of P position Shiftlock Solenoid N110 blocks selector lever Brake pedal depressed Shiftlock Solenoid N110 releases selector lever It is now possible to shift into a driving gear Page 1 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT0...

Page 115: ...ove 5 km h 3 mph and shifting into selector lever position N the Shiftlock Solenoid N110 must not engage and block the selector lever The selector lever can be shifted into a driving gear When travelling at speeds below 5 km h 3 mph almost stopped and shifting into selector lever position N the Shiftlock Solenoid N110 must not engage until after approx 1 second The selector lever cannot be shifted...

Page 116: ...ansmission lever after dismantling Adjusting Selector lever in P position Loosen selector lever cable combi bolt on selector shaft lever Bring selector shaft lever into position P on transmission Locking lever must engage in park lock wheel both front wheels locked In this position tighten selector shaft lever combi bolt Tightening torque 25 Nm 18 ft lb Page 3 of 25 Shift mechanism servicing 12 6 ...

Page 117: ... be possible to remove ignition key with selector lever in P position Remove ignition key Selector lever cannot be shifted out of P position Page 4 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 118: ...ring locking cable Always replace 4 Selector lever handle 5 Set screw Tightening torque 1 5 Nm 13 in lb 6 Cover With selector indicator 7 Protective sleeve For selector lever 8 Cover strip Insert in cover 6 Page 5 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 119: ...rd When installing selector lever insert locking cable anchor in notch of selector lever housing Securing wiring harness to selector lever housing Shiftlock Solenoid with single wiring harness Fig 2 Page 6 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 120: ...to replace selector lever cable or individual parts of shift mechanism Removing and installing Fig 1 14 Screw Tightening torque 25 Nm 18 ft lb Page 7 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 121: ...o selector lever housing before attaching selector lever cable 17 Hex nut With shoulder Tightening torque 25 Nm 18 ft lb Page 8 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 122: ...ghten selector lever cable on cable anchor selector lever housing to 20 Nm 15 ft lb Check guide tube for tight fit Check protective sleeve between console and lever gearshift shaft for proper seating and secure selector lever cable with corrugated locking element 28 Attach selector lever cable to selector lever Fig 3 Adjusting page 37 3 Page 9 of 25 Shift mechanism servicing 12 6 2004 http ebahn b...

Page 123: ...ctor shaft 25 Bracket With cable anchor for selector lever cable 26 Washer 27 Combi bolt Tightening torque 25 Nm 18 ft lb 28 Corrugated locking element For selector lever cable Always replace Page 10 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 124: ...n Sensor connector separate exhaust system in front of Three Way Catalytic Converter TWC Remove front protective plate and rear lower bolts arrows Fig 2 Mounting wiring harness to selector lever housing Press wiring harness into clips and into selector lever housing arrows Page 11 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair ...

Page 125: ...r Fit selector lever cable eye arrow onto selector lever and secure with circlip Page 12 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 126: ...1 Selector lever Assembling Fig 1 2 Indicator lighting Mounting indicator lighting connector Fig 4 3 Spring 4 Push rod Grease in area of sliding surfaces Page 13 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 127: ... by turning selector lever Install with thread locking fluid AMV185 101 A1 7 Shiftlock Solenoid N110 Adjusting Fig 2 Functional check Fig 3 Can be checked by On Board Diagnostic OBD program page 01 20 Page 14 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 128: ...tion lock Adjust together with locking cable page 37 25 12 Spring Hook into hole of detent plate 13 Retainer For locking cable Removing and installing locking cable page 37 21 Adjusting locking cable page 37 25 Page 15 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 129: ...ket 17 Socket head screw Tightening torque 6 Nm 53 in lb 18 Screw Tightening torque 6 Nm 53 in lb 19 Washer 20 Spring Insert in selector lever together with lever 21 Page 16 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 130: ...g 2 22 Bushing 23 Nut Tightening torque 10 Nm 7 ft lb Always replace 24 Combi bolt Grease shank Page 17 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 131: ...Shiftlock Solenoid N110 mounting screws with thread locking fluid AMV 185 101 A1 Fig 2 Adjusting Shiftlock Solenoid N110 Adjust solenoid by sliding in elongated holes until correct clearance a exists between push rod and lever Fig 3 Page 18 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCa...

Page 132: ...ctor lever into a driving gear Interrupt solenoid operation It must now be possible to shift into driving gears Push rod must not catch on lever Shift selector lever into N and check as in P After adjusting clearance install assembled selector lever Page 19 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW A...

Page 133: ... Push bracket with lug arrow on until lug engages Seat connector cable into bracket and slide connector onto bracket Page 20 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 134: ... Loosen cable anchor screw take locking cable out of locking lever and pull out of cable anchor Remove locking cable from clip arrow Remove trim pieces from ignition starter switch Press locking cable clip out of ignition starter switch and remove locking cable from ball head Take out locking cable Page 21 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Displa...

Page 135: ...installing Install locking cable in vehicle Mount locking cable eye 1 on locking lever a Page 22 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 136: ...e clip on locking cable first Press locking cable onto ball head Press locking cable with clip into support bracket for Ignition Starter Switch Page 23 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 137: ...page 37 25 Install center console Install cover with indicator and selector lever handle Attach trim for Ignition Starter Switch Page 24 of 25 Shift mechanism servicing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 1 WWW ALL TRANS BY ProCarManuals com ...

Page 138: ...locking cable anchorage screw in this position Tightening torque 6 Nm 53 in lb Shift selector lever into P position and turn ignition key to end OFF position Remove ignition key It must only be possible to remove ignition key with selector lever in P position It must not be possible for selector lever to be shifted out of P position Page 25 of 25 Shift mechanism servicing 12 6 2004 http ebahn bent...

Page 139: ...tall speed checking Measuring stall speed page 37 30 Main pressure measuring Measuring main pressure page 37 32 Page 1 of 8 Transmission checking 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 2 WWW ALL TRANS BY ProCarManuals com ...

Page 140: ...d System in basic setting Check transmission fluid ATF level Page 37 43 Check engine settings Repair Manual for the appropriate engine Fuel Injection Ignition Repair Group 24 Page 2 of 8 Transmission checking 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 2 WWW ALL TRANS BY ProCarManuals com ...

Page 141: ...ch is built into the Transmission Control Module TCM The ECO or Sport program will be automatically selected by the TCM according to the speed at which the Accelerator Pedal is depressed For transmissions with the electronic program switch only kick down shift points are given To check the shift points connect VAG 1551 Scan Tool ST Repair Group 01 Reading measured value block Page 3 of 8 Transmiss...

Page 142: ...2 122 128 76 80 176 182 109 113 178 172 111 107 119 113 74 70 50 44 31 27 CNK 85 kW 115 hp engine 1 H 2 H 2 H 3 H 3 H 4 M 4 M 3 H 3 H 2 H 2 H 1 H 51 57 32 35 99 107 62 66 144 153 89 95 147 140 91 87 98 92 61 57 46 40 29 25 Page 4 of 8 Transmission checking 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 2 WWW ALL TRANS BY ProCarManuals com ...

Page 143: ...specified stall speed is not attained the following malfunctions are probable causes Symptom Probable cause Stall speed too high Forward clutch slipping free wheel slipping Stall speed up to 200 rpm too low Check engine settings Stall speed more than 200 rpm too low Torque converter malfunctioning In cases of doubt the engine settings must always be checked first and if necessary corrected The tra...

Page 144: ...ission 096 Torque converter Code letters Stall speed RPM CFF QCCR 2350 2650 CNK QACA 2750 3050 Page 6 of 8 Transmission checking 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 2 WWW ALL TRANS BY ProCarManuals com ...

Page 145: ...main pressure drilling plug Always replace main pressure drilling plug Connect pressure gauge VAG 1702 and tighten knurled screw Bleed pressure gauge VAG 1702 line by loosening knurled screw with engine running Bring automatic transmission fluid ATF temperature to 60 C 140 F to do this connect VAG 1551 Scan Tool ST and read temperature in measured value block Page 7 of 8 Transmission checking 12 6...

Page 146: ...64 23 0 24 0 334 348 1 After reconnecting the Solenoid Valve connector check and erase DTC Memory Repair Group 01 On Board Diagnostic If main pressure deviates from specified values the following are possible causes and recommended remedies Possible cause Remedy Idle speed too high Adjust ATF pump malfunctioning Check ATF pump replace if necessary Control valve sticking in valve body Replace valve...

Page 147: ... at transmission Remove electrical connections arrows at transmission Move selector lever to P and disconnect selector lever cable from lever selector shaft Remove selector lever cable anchor circlip and remove selector lever cable Page 1 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS ...

Page 148: ...ansmission mounting bolts Remove Starter Install support bar 10 222 A with legs 10 222 A 1 6 cyl engine adapter 10 222 A 3 and support engine transmission in this position Page 2 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS BY ProCarManuals com ...

Page 149: ... Remove coolant expansion tank and set aside Remove left engine mount complete On vehicles with 6 cylinder engine remove drive belt cover Disconnect axle shafts at transmission drive flanges Remove left wheel Page 3 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS BY ProCarManuals com ...

Page 150: ...and loosen bolts B Swing ball joint outward and place left side axle shaft to one side Vehicles with tripodic star shaped joint remove drive shaft Disconnect harness connector from Multi function Transmission Range TR Switch and remove switch Remove ATF oil pan protective plate Page 4 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Got...

Page 151: ...engine using support device spindle Transmission mount 3282 is set up with the adjusting plate 3282 2 for removing the automatic transmission 096 The symbols on the adjusting plate indicate the mounts required Set up gearbox mount 3282 Page 5 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TR...

Page 152: ...ngine transmission connecting bolts Pry transmission off engine when doing this press torque converter out of drive plate Press torque converter against ATF pump Lower transmission slightly Page 6 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS BY ProCarManuals com ...

Page 153: ...the automatic gearbox Special tool 3336 may be used to transport the automatic gearbox and also when setting up gearbox mount 3282 Secure special tool 3336 to gearbox housing flange arrow Position pins so that 8 holes are visible in chain direction Page 7 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37...

Page 154: ...g ensure that dowel sleeves for aligning the engine and transmission are correctly located Replace selector cable anchor locking washer Check selector lever cable adjustment adjust if necessary page 37 3 Page 8 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS BY ProCarManuals com ...

Page 155: ...ly 60 Nm 44 ft lb Left mount to mounting assembly 60 Nm 44 ft lb Left mount to transmission 25 Nm 18 ft lb Cover plate to transmission 15 Nm 11 ft lb Ball joint to control arm 35 Nm 26 ft lb Starter to transmission 60 Nm 44 ft lb Page 9 of 9 Transmission removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 3 WWW ALL TRANS BY...

Page 156: ...ore be checked at regular intervals When cold the ATF should be visible up to the 20 C marking Bring ATF up to normal operating temperature approx 60 C 140 F Operating temperature is measured with VAG 1551 Scan Tool ST page 01 40 Reading measured value block Check ATF level again and top up or extract as necessary It is essential that the ATF level is between the Min and Max markings Page 1 of 2 A...

Page 157: ...irst for an initial filling Then start engine and shift through all the selector lever positions with the vehicle stationary Check ATF level page 37 43 Use a non fluffing cloth for wiping off the dipstick The ATF level changes with the temperature of the fluid The Min and Max markings on the dipstick refer to the correct levels for an ATF temperature of 60 C 140 F Page 2 of 2 ATF level 12 6 2004 h...

Page 158: ...complaints of poor performance or for general drivetrain troubleshooting The table makes it possible to determine which selector elements are not operating properly 1 2nd and 4th gear brake B2 2 Reverse gear clutch K2 3 1st to 3rd gear clutch K1 4 4th gear clutch K3 5 Reverse gear brake B1 6 Free wheel clutch Page 1 of 2 Gear selector elements 12 6 2004 http ebahn bentleypublishers com vw servlet ...

Page 159: ...Module TCM Gear B1 B2 K1 K2 K3 F R x x 1H x x 2H x x 3H x x 4M x x X clutch brake or free wheel engaged H hydraulic M mechanical Page 2 of 2 Gear selector elements 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 5 WWW ALL TRANS BY ProCarManuals com ...

Page 160: ...49 Planetary gearbox disassembling page 37 61 Planetary gearbox assembling page 37 67 Planetary gearbox adjustments overview page 37 79 Valve body removing and installing page 38 22 Page 1 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 161: ...oler 4 O ring Always replace 5 Transmission housing 6 ATF dipstick Checking ATF level page 37 43 7 ATF filler tube 8 Bolt 9 O ring Always replace Page 2 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 162: ...38 22 I ATF pump to support tube removing and installing page 37 51 II Reverse gear clutch K2 to large sun gear removing and installing page 37 54 III Free wheel and reverse gear brake B1 removing and installing page 37 57 Page 3 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ...

Page 163: ... not necessary to remove the input gear arrow Removing and installing input gear page 39 8 Page 4 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 164: ...itional 1 4 turn 90 The additional 1 4 turn 90 may be done in several stages 2 ATF pump with B2 piston Disassembling and assembling page 38 1 3 O ring Always replace Install on ATF pump 4 Gasket Always replace Page 5 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals...

Page 165: ...tity from page 00 3 Determining thickness of outer plate page 37 101 2nd and 4th gear brake B2 adjusting 9 Inner plate B2 Quantity from page 00 3 Before installing place new inner plates in ATF for 15 minutes Page 6 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals ...

Page 166: ...age Length of B2 with 4 inner plates 72 3 mm 2 846 in with 5 inner plates 68 6 mm 2 701 in with 6 inner plates 64 9 mm 2 555 in Quantity of B2 inner plates from page 00 3 Insert so that groove engages in wedge of free wheel Page 7 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY...

Page 167: ...Reverse gear clutch K2 Disassembling and assembling page 38 13 2 Shim Determining thickness page 37 94 Clutch play between K1 and K2 adjusting 1 or 2 shims can be installed Page 8 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 168: ...ng 6 Axial needle bearing washer Lugs face toward axial needle bearing 7 4th gear clutch K3 with pump shaft Disassembling and assem bling page 38 17 Page 9 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 169: ...2 Large drive shaft 13 Axial needle bearing 14 Axial needle bearing washer With shoulder 15 Large sun gear 16 Axial needle bearing 17 Axial needle bearing washer Page 10 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 170: ...r free wheel 3 Free wheel with B1 piston Before removing free wheel remove valve body and sealing plugs page 38 22 Disassembling and assembling page 38 4 4 Dished spring Install with convex part facing free wheel Page 11 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarMan...

Page 171: ...0 5 mm 0 413 in 6 Inner plate B1 Quantity from page 00 3 Before installing place in ATF for 15 minutes 7 Outer plate B1 Quantity from page 00 3 8 Shim Determining thickness page 37 87 Reverse gear brake B1 adjusting Page 12 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCar...

Page 172: ... 80 2 O ring Always replace Insert in planet carrier 3 Axial needle bearing washer 4 Axial needle bearing 5 Axial needle bearing washer Install smooth side in input gear 6 Transmission housing Page 13 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 173: ...80 Planet carrier adjusting 9 Washer 10 Bolt Tightening torque 30 Nm 22 ft lb For small input shaft 11 Spacer bush Qty 7 Clip into gasket 12 Gasket Always replace 13 Cover 14 Bolt Tightening torque 8 Nm 71 in lb Page 14 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManu...

Page 174: ... 1358A 1 probe or EZ1 fluid evacuator Remove torque converter Secure transmission to assembly support with bolts 1 and 2 Remove transmission housing cover with gasket arrow Page 15 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 175: ... 22 Remove valve body Remove sealing plugs for B1 Page 16 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 176: ...nsmission by turning bolts A evenly Take out all clutches with supporting tube B2 plates springs and spring caps together Page 17 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 177: ...t bolt arrow Remove small drive shaft bolt washer and shim Planet carrier axial needle bearing remains in transmission input gear Pull out small drive shaft Page 18 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 178: ...t arrow Pull out large sun gear arrow Page 19 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 179: ...ar page 39 8 Assembling planetary gearbox page 37 67 Pull out planet carrier with dished spring Remove reverse gear brake B1 plates It is not necessary to remove input gear to disassemble the planetary gearbox Page 20 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManual...

Page 180: ...mooth side into input gear 4 Input gear Installed in transmission housing page 37 49 Note After replacing planet carrier adjust page 37 80 Install O ring in planet carrier Page 21 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 181: ...asher 3 Planet carrier Install planet carrier into input gear Center washer and axial needle bearing in small sun gear Page 22 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 182: ...e When replacing adjust B1 page 37 87 Install dished washer with convex side facing toward free wheel Transmission housing Free wheel Piston for reverse gear brake B1 or plates Page 23 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 183: ...or supporting tube Install so that circlip gaps are over free wheel retaining wedge arrow Carry out check measurement of B1 page 37 93 Page 24 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 184: ...acing axial needle bearing 3 Large sun gear Install large sun gear with bearing Center both washers with axial needle bearing between sun gears Page 25 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 185: ...in large drive shaft Install large drive shaft with bearing Page 26 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 186: ... shim 3 onto small drive shaft shoulder arrow Determining shim thickness page 37 80 Planet carrier adjusting Carry out planet carrier check measurement Page 27 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 187: ... clutch K3 Install axial needle bearing with washer on 4th gear clutch K3 1 Axial needle bearing with washer Moisten axial needle bearing washer with ATF so that bearing 1 while installing sticks to K3 Install bearing washer on K3 2 4th gear clutch K3 Page 28 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW ...

Page 188: ...K1 K2 or ATF pump page 37 94 Clutch play between K1 and K2 adjusting 1 or 2 shims can be installed Page 29 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 189: ...ting tube for plate set B2 arrow so that supporting tube groove engages in free wheel wedge Page 30 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 190: ...hen replacing the 2nd and 4th gear brakes B2 are to be adjusted page 37 101 Before installing the last outer plate install three spring caps onto compression springs Supporting tube the ATF pump or the plates Page 31 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals...

Page 191: ...urn can be done in several stages Make sure that the O ring is not damaged Carry out check measurement of clutch play page 37 100 Install sealing plugs valve body and oil pan page 38 22 Install cover with gasket and spacer bushings Page 32 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL...

Page 192: ... 101 2nd and 4th gear brake B2 adjusting III Planet carrier C Shim Determining thickness page 37 80 Planet carrier adjusting IV Clutch play D Shim Determining thickness page 37 94 Clutch play between K1 and K2 adjusting Page 33 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY Pr...

Page 193: ...ut gear Damaged axial needle bearing page39 8 Input gear removing and installing 2 Axial needle bearing washer Insert smooth side in input gear 3 Axial needle bearing 4 Axial needle bearing washer 5 O ring Insert into planet carrier page 37 67 Planetary gearbox assembling Page 34 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Go...

Page 194: ...shaft 13 Axial needle bearing 14 Needle bearing 15 Small drive shaft 16 Shim Do not install in planet carrier when adjusting 17 Washer 18 Small drive shaft bolt Tightening torque 30 Nm 22 ft lb Page 35 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 195: ...on housing Insert screwdriver through hole of large drive shaft and large sun gear to loosen and tighten bolt for small drive shaft Page 36 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 196: ...m preload Zero dial gauge Move small input shaft up and take measurement Example measurement 2 00 mm Specify thickness of shim according to table and determine Part No from parts catalog microfiche Page 37 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 197: ...5 2 06 2 15 1 6 1 7 1 8 2 16 2 25 2 26 2 35 2 36 2 45 1 9 2 0 2 1 2 46 2 55 2 56 2 65 2 66 2 75 2 2 2 3 2 4 2 76 2 85 2 86 2 95 2 96 3 05 2 5 2 6 2 7 3 06 3 15 3 16 3 25 2 8 2 9 Page 38 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 198: ...t shaft arrow Tighten small input shaft bolt 1 with washer 2 Tightening torque 30 Nm 22 ft lb Carry out planet carrier check measurement Page 39 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 199: ...x assembling page 37 67 Insert dial indicator in VW 382 7 measuring bar and place the tip on the small input shaft bolt Move small input shaft up and down and measure axial play on dial indicator min 0 23 mm 0 0091 in max 0 37 mm 0 0146 in Page 40 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6...

Page 200: ...ll with flat side facing plates Differing thicknesses depending on number of inner plates installed Thickness with 4 inner plates 13 5 mm 0 531 in Thickness with 5 inner plates 10 5 mm 0 413 in Quantity of B1 inner plates from page 00 3 Page 41 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WW...

Page 201: ... page 38 22 6 Dished washer Convex side faces towards free wheel 7 Free wheel with B1 piston 8 Circlip Page 42 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 202: ...in free wheel m Height of plate set including thrust plate K Constant 26 8 mm Constant is determined by installation height in transmission housing and is not adjustable Page 43 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 203: ...ce of free wheel Measure to inner edge of piston with depth gauge B Measurement 51 8 mm Straightedge height 48 2 mm Calculated dimension l 3 6 mm Page 44 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 204: ... thickness of plate set with depth gauge B Measurement 73 5 mm Straightedge height 48 2 mm Calculated dimension m 25 3 mm 26 8 3 6 2 25 3 3 3 mm Determine size of shims according to table Page 45 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 205: ...1 1 1 1 1 1 2 1 2 1 2 3 86 3 95 3 96 4 05 4 06 4 15 1 2 1 3 1 3 1 3 1 3 1 4 4 16 4 25 1 4 1 4 Determine thickness of shims according to table and determine Part No from parts catalog microfiche After determining shim for B1 carry out check measurement page 37 93 Page 46 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type re...

Page 206: ...x assembling page 37 67 Specifications Measure clearance between plates with feeler gauge A minimum 1 20 mm maximum 1 80 mm Page 47 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 207: ... with washer Axial needle bearing faces towards small input shaft Washer faces toward K3 3 4th gear clutch K3 with pump shaft 4 Axial needle bearing washer Lugs face toward axial needle bearing Page 48 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 208: ...not install when adjusting clutch play 1 or 2 shims may be installed to achieve correct thickness 9 Reverse gear clutch K2 Page 49 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 209: ...3 1st to 3rd gear clutch K1 4 4th gear clutch K3 Determine gap x and calculate shim thickness Page 50 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 210: ... 3 mm Dimension measured from pump flange transmission housing into K1 Measure with depth gauge B to pump flange on transmission housing Measurement 1 88 5 mm Measurement 2 34 3 mm Calculated dimension a 54 2 mm Page 51 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManu...

Page 211: ...e with depth gauge A to gasket of pump flange Measurement 70 5 mm Straightedge height 19 5 mm Calculated dimension b 51 0 mm Page 52 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 212: ... 05 5 25 1 2 1 2 1 6 1 2 1 2 1 8 Determine thickness of shims according to table and determine Part No from parts catalog microfiche Carry out clutch play check measurement after installing ATF pump Page 53 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 213: ...e on turbine shaft with a 1 mm preload Specifications Move turbine shaft up and down and read axial play on dial indicator gauge minimum 0 5 mm 0 020 in maximum 1 2 mm 0 047 in Page 54 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 214: ...r supporting tube 3 Supporting tube B2 Length of B2 4 inner plates 72 3 mm 2 847 in 5 inner plates 68 6 mm 2 701 in 6 inner plates 64 9 mm 2 555 in Quantity inner plates B2 from page 00 3 Insert so that notch locates on free wheel wedge Page 55 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WW...

Page 215: ...er plate 6 Outer plate B2 Always install 2 mm thick outer plates Quantity from page 00 3 Page 56 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 216: ...plate B2 Do not install when adjusting B2 2 outer plates can be installed 11 Corrugated washer Do not install when adjusting B2 Page 57 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 217: ... is selected from table page 37 106 Gap x a b 3 6 mm Note First outer plate arrow is always 3 mm thick A Outer plate Page 58 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY ProCarManuals com ...

Page 218: ...Example Gap x a b 3 6mm Place straightedge B onto stator support arrow and measure with depth gauge A to gasket of pump flange Measurement 40 1 mm Straightedge height 19 5 mm Calculated size b 20 6 mm 30 2 20 6 6 00 mm Page 59 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 37 6 WWW ALL TRANS BY Pro...

Page 219: ... 25 2 25 2 25 2 50 6 50 6 74 6 75 7 00 2 50 2 50 2 50 2 75 Determine thickness of outer plate according to table and determine Part No from parts catalog microfiche Two outer plates can be installed if necessary to achieve the specified thickness Page 60 of 60 Transmission disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT...

Page 220: ...ing Check that ring is correctly located Fig 1 Installing Fig 2 4 Thrust washer 5 Piston Sealing lips are vulcanized to piston Moisten sealing lips with ATF before installing Turn piston slightly while installing Page 1 of 3 ATF pump disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 1 WWW ALL TRANS BY ProCarManuals c...

Page 221: ...y not operate freely in the installed position 9 Inner gear Larger groove faces stator support 10 Housing for ATF pump 11 O ring Always replace 12 Torque converter oil seal Removing and installing page 32 4 Page 2 of 3 ATF pump disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 1 WWW ALL TRANS BY ProCarManuals com ...

Page 222: ...ring together Place piston ring in groove To hook ends together press sides of ring in and guide ends over one another Do not twist piston ring out of groove on one side Page 3 of 3 ATF pump disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 1 WWW ALL TRANS BY ProCarManuals com ...

Page 223: ...g 5 Piston Sealing lips are vulcanized to piston Moisten sealing lips with ATF before installing Turn piston slightly while installing Installed position Fig 4 Page 1 of 3 Free wheel with B1 piston disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 2 WWW ALL TRANS BY ProCarManuals com ...

Page 224: ...e Fig 2 Installing cage with springs and rollers Install with large lugs arrow facing up Page 2 of 3 Free wheel with B1 piston disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 2 WWW ALL TRANS BY ProCarManuals com ...

Page 225: ...r as stop Fig 4 Installed position of piston Install piston A as shown Page 3 of 3 Free wheel with B1 piston disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 2 WWW ALL TRANS BY ProCarManuals com ...

Page 226: ...for different clutch assemblies Mark after removing and install in same position 4 Thrust plate Smooth side faces inner plate Install together with plate carrier Fig 2 5 Inner plate Quantity page 00 3 Installing Fig 2 Page 1 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 A...

Page 227: ... are vulcanized to cap Moisten sealing lips with ATF before installing Turn cap slightly while installing 11 Intermediate spring ring With spring supporting shell and compression springs Page 2 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 3 WWW ALL TRANS BY ProCa...

Page 228: ... 15 Clutch housing with turbine shaft Check bearing bushings Replace housing if bushings are damaged Before inserting inner plate carrier corrugated washer 8 insert inner and outer plates in clutch Fig 3 16 Piston ring Check that ring is correctly located Fig 5 Installing Fig 6 Page 3 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublish...

Page 229: ...rd inner plate carrier Install 3 inner plates b and 2 outer plates c Insert supporting ring with step arrow after installing thrust plate as well as inner and outer plates Locate locating lugs correctly Installing corrugated washer and additional plates in clutch housing Fig 3 Page 4 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishe...

Page 230: ...inner and outer plates Fig 4 Inserting inner plate carrier and installing circlip Lift inner plate carrier slightly to install circlip arrow Page 5 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 3 WWW ALL TRANS BY ProCarManuals com ...

Page 231: ...nd hooking ends of piston ring together Place piston ring in groove To hook ends together press sides of ring in and guide ends over one another Do not twist piston ring out of groove on one side Page 6 of 6 1st to 3rd gear clutch K1 with turbine shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 3 WWW ALL TRANS...

Page 232: ...ll in same position 2 Thrust plate Smooth side facing inner plates Thickness with clutches of 4 inner plates 6 5 mm 0 256 in 5 inner plates 4 9 mm 0 193 in 3 Outer plate Quantity page 00 3 Page 1 of 4 Reverse gear clutch K2 disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 4 WWW ALL TRANS BY ProCarManuals com ...

Page 233: ... Installation position Fig 2 7 Spring supporting plate With springs Installation position Fig 2 Page 2 of 4 Reverse gear clutch K2 disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 4 WWW ALL TRANS BY ProCarManuals com ...

Page 234: ...ith ATF before installing Turn piston slightly while installing 10 Clutch housing with clutch tube Page 3 of 4 Reverse gear clutch K2 disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 4 WWW ALL TRANS BY ProCarManuals com ...

Page 235: ...ve to hub otherwise spring supporting plate will be bent Fig 2 Installation position of spring supporting plate checking circlip Circlip arrow must be seated in the groove of clutch housing Spring supporting plate must be centered relative to hub Page 4 of 4 Reverse gear clutch K2 disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id ...

Page 236: ...nstall in same position 2 Thrust plate Install with stepped side facing circlip 3 Inner plate Quantity page 00 3 4 Outer plate Quantity page 00 3 Page 1 of 5 4th gear clutch K3 with pump shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 5 WWW ALL TRANS BY ProCarManuals com ...

Page 237: ...ston cap Moisten with ATF before installing Turn piston cap slightly when installing When removing and installing press down and fit circlip item 7 9 Spring Seat between piston and piston cap Page 2 of 5 4th gear clutch K3 with pump shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 5 WWW ALL TRANS BY ProCarManu...

Page 238: ...on ring Replace only faulty piston rings Piston ring is destroyed when removed Check that ring is correctly located Fig 2 Installing Fig 3 13 Piston ring Check that ring is correctly located Fig 2 Installing Fig 3 Page 3 of 5 4th gear clutch K3 with pump shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 5 WWW A...

Page 239: ... shaft inside the clutch housing arrow Fig 2 Checking that piston rings are correctly located Make sure that ends of piston rings are hooked together Page 4 of 5 4th gear clutch K3 with pump shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 5 WWW ALL TRANS BY ProCarManuals com ...

Page 240: ...s sides of ring in and guide ends over one another Do not twist piston ring out of groove on one side Page 5 of 5 4th gear clutch K3 with pump shaft disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 5 WWW ALL TRANS BY ProCarManuals com ...

Page 241: ... is installed On vehicles with 6 cylinder engine remove starter After re installing the oil pan fill with ATF page 37 43 Always replace a valve body that is fouled or malfunctioning 1 Oil pan 2 Bolt Tightening torque 12 Nm 9 ft lb Page 1 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ...

Page 242: ...g Fig 4 7 Gasket Always replace Press into ATF screen 8 Bolt Tightening torque 5 Nm 44 in lb 9 Valve body Marking Fig 5 Installing Fig 2 Removing and installing conductor strip only page 38 29 Page 2 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 243: ...tening torque 10 Nm 7 ft lb 17 Sealing plug Take out before removing and installing free wheel Insert so that lug is located in groove on housing Fig 1 Place O rings onto sealing plug Page 3 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 244: ...manual selector valve Adjusting Fig 3 Install with stepped side facing manual selector valve Page 4 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 245: ...stalling sealing plug Conductor strip removing and installing page 38 29 Fig 2 Installing valve body Route conductor strip as illustrated When installing do not kink or twist Page 5 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 246: ... and tighten bolt Tightening torque 4 Nm 35 in lb The manual selector valve must always be resting against the stop Counter hold in direction of arrow when tightening bolt Always replace manual selector valve bolt Page 6 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com...

Page 247: ...metal tab The metal tab must remain on the valve body Vehicle transmission applications page 00 3 Fig 5 Identification of valve body Page 7 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 248: ...ATF pan Disconnect conductor strip harness connector Remove ATF pan and ATF screen Note If the locating points are damaged the valve body must be replaced Place special tool 3373 into position on stop under solenoid valve connector and pry conductor strip off in direction shown arrow Remove bolt 1 and remove conductor strip Page 8 of 9 Valve body removing and installing 12 6 2004 http ebahn bentle...

Page 249: ... Conductor strip to trans housing 10 Nm 7 ft lb ATF screen to valve body 8 Nm 71 in lb ATF pan to trans housing 12 Nm 9 ft lb Add 3 liters 3 2 US qt ATF check ATF level and top up as necessary page 37 43 Page 9 of 9 Valve body removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 6 WWW ALL TRANS BY ProCarManuals com ...

Page 250: ...to disassemble and assemble the parking lock page39 14 Drive pinion removing and installing 1 Return spring Installing Fig 4 2 Detent lever Installing with return spring Fig 4 3 Parking lock gear Rounded side faces teeth of drive pinion 4 Bolt Tightening torque 14 Nm 10 ft lb Page 1 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action ...

Page 251: ... with selector segment 10 Bolt Tightening torque 10 Nm 7 ft lb 11 Locking washer 12 Engaging lever Insert with selector shaft and detent segment 13 Spring pin Drive in after installing engaging lever and detent segment Fig 1 Drive out with drift Page 2 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 ...

Page 252: ...eal Pry out with screwdriver Drive in flush with VW 423 20 O ring Always replace 21 Multi Function Transmission Range TR Switch F125 Install so that 1 pin each is resting on a slope of the detent segment Can be tested in vehicle by On Board Diagnostic program page 01 20 Page 3 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto t...

Page 253: ...or detent lever Secured by circlip and bearing cap of drive pinion According to version with groove for circlip 27 Circlip Always replace Only install on shafts with groove for circlip 28 Washer Page 4 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 7 WWW ALL TRANS BY ProCarManuals com ...

Page 254: ...etent segment Note Fig 2 Removing and installing selector shaft with selector segments Remove bolt arrow and washer The washer is placed into the groove of the selector shaft and secures the shaft to keep it from dropping out The selector shaft can be removed or installed after taking out the spring for the selector segment Page 5 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn...

Page 255: ...rting plate Fig 4 Installing pawl with return spring Page 6 of 6 Parking lock disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 38 7 WWW ALL TRANS BY ProCarManuals com ...

Page 256: ...raction system or EZ1 fluid evacuator Checking Remove speedometer drive shaft and clean using a cloth Install and remove speedometer drive shaft and if necessary correct oil level Final drive oil level must be between Min and Max Page 1 of 1 Oil in final drive checking 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 1 WWW ALL TRANS BY ProCarMa...

Page 257: ...and oil seal Mark installation position of ball joint control arm mounting bolts and Remove outer bolts arrow A Loosen inner bolt arrow B Turn steering to right full lock Swing ball joint out and place left hand drive shaft to one side Page 1 of 4 Drive flange oil seal removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 2 W...

Page 258: ...rive flange with VW 391 Pull out drive flange oil seal with VW 681 Page 2 of 4 Drive flange oil seal removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 2 WWW ALL TRANS BY ProCarManuals com ...

Page 259: ... dust lip with multi purpose grease Install drive flange dished washer and circlip Note Drive flange can also be pulled in with VW 391 Pull drive flange in Page 3 of 4 Drive flange oil seal removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 2 WWW ALL TRANS BY ProCarManuals com ...

Page 260: ... check final drive oil level page 39 1 Tightening torque Drive shaft to drive flange 45 Nm 33 ft lb Ball joint to control arm 35 Nm 26 ft lb Page 4 of 4 Drive flange oil seal removing and installing 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 2 WWW ALL TRANS BY ProCarManuals com ...

Page 261: ...een removed 1 Planetary gear Disassembling and assembling page 37 49 2 Input gear Removing and installing page 39 8 Adjusting page 39 48 Adjusting final drive overview page 39 41 Page 1 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 262: ...l Removing and installing page 39 23 Disassembling and assembling page 39 33 Adjusting page 39 51 Adjusting final drive overview page 39 41 Page 2 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 263: ...l Use 22 mm hex wrench Before installing socket head fastener insert axial needle bearing 7 2 Dished washer Curved side faces socket head fastener 3 Shim Determining thickness page 39 48 Input gear adjusting Page 3 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals co...

Page 264: ...roller bearing outer race Drive out with drift Drive in with tool 30 205 Install with AMV 185 101 A1 locking fluid 6 Transmission housing 7 Axial needle bearing Install with flat side facing input gear Insert into input gear before installing socket head fastener 1 Page 4 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type r...

Page 265: ...n Fig 2 Installation position Fig 4 Install with AMV 185 101 A1 locking fluid 10 Input gear With impulse wheel for Vehicle Speed Sensor VSS G68 Number of teeth page 00 3 Technical data Adjusting page 39 48 If signs of damage exist always replace input gear and output gear together Removing Fig 5 Page 5 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw ser...

Page 266: ... placed below the hub of the input gear to avoid damaging the input gear Fig 2 Pressing on tapered roller bearing inner race Page 6 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 267: ...w Fig 4 Note Tapered roller bearings without lugs can also be installed Fig 4 Installation position of tapered roller bearing inner race Lug arrow must engage in groove of the opposite inner race Page 7 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 268: ... tapered roller bearing inner race Gap a approx 3 mm 0 118 in Drive out input gear with VW 771 as far as the stop of the tapered roller bearing inner race Remove VW 771 and remove input gear Page 8 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 269: ...om page 00 3 Technical data Adjusting page 39 44 Removing Fig 8 2 Transmission housing 3 Screw Tightening torque 12 Nm 9 ft lb Remove screw before removing or installing bearing supporting ring 12 Install with AKD45600001 sealing compound Page 9 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WW...

Page 270: ...nput gear and output gear together 6 Tapered roller bearing inner race Pulling off Fig 2 Pressing on Fig 3 7 Tapered roller bearing outer race Drive out with drift Pressing in Fig 4 8 Bolt Tightening torque 25 Nm 18 ft lb 9 Bearing cap Page 10 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ...

Page 271: ...or installing Fig 5 Bearing support ring cannot be unscrewed until the selector shaft has been removed page 38 31 Parking lock disassembling and assembling Install bearing supporting ring carefully Sealing lip and spring must not be damaged Supporting ring with seal Fig 6 Page 11 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Got...

Page 272: ... 6 Driving in Fig 7 15 Tapered roller bearing outer race Driving in Fig 9 16 Tapered roller bearing inner race Drive off with drift Pressing on Fig 10 Page 12 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 273: ... Pulling off tapered roller bearing inner race Place press piece onto collar of output gear Page 13 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 274: ...r race Fig 4 Pressing in tapered roller bearing outer race Page 14 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 275: ...with thread sealing compound AKD45600001 Installation position of seal Fig 6 Bearing supporting ring with seal for drive pinion Open side arrow faces toward tapered roller bearing outer race Page 15 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 276: ... that sealing lip faces special tool 30 204 Fig 8 Removing drive pinion Page 16 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 277: ...ler bearing inner race then drive in outer race Fig 10 Pressing on tapered roller bearing inner race Page 17 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 278: ...sing 2 Speedometer drive With marking for oil level indication Fig 7 3 Output shaft drive flange Install thread facing drive flange Remove before taking out differential First adjust differential before installing 4 O ring Always replace Page 18 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WW...

Page 279: ...ange Before installing pack space between sealing lips with multi purpose grease Can be replaced with transmission installed page 39 2 Remove with VW 681 Driving in Fig 1 7 Tapered ring Shoulder faces thrust washer 8 Thrust washer Place over compression spring 9 Compression spring Page 19 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display a...

Page 280: ...and installing Fig 4 11 Dished washer 12 Circlip 13 Cover 14 Locking element 15 Screw Tightening torque 12 Nm 9 ft lb 16 Cover 17 Circlip 18 Dished washer Page 20 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 281: ...g 22 Tapered ring Shoulder faces thrust washer 23 Oil seal for drive flange Before installing pack space between sealing lips with multi purpose grease Can be replaced with transmission installed page 39 2 Remove with VW 681 Driving in Fig 1 Page 21 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 ...

Page 282: ...ange Before removing take out differential First adjust differential before installing 27 Differential Disassembling and assembling page 39 33 Before removing differential take out bearing body adjusting ring and output shafts 28 Screw Tightening torque 12 Nm 9 ft lb 29 Locking element Page 22 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Disp...

Page 283: ...ve drive flange before removing circlip Removing and installing Fig 6 32 Seal Always replace 33 Cover For differential 34 Screw Tightening torque 28 Nm 21 ft lb Install with thread locking fluid AMV 185 101 A1 Page 23 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals...

Page 284: ...are re installed mark installation position arrow and use marking to position adjusting ring when installing Page 24 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 285: ...o be removed with VW 391 Fig 4 Removing and installing drive flange Page 25 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 286: ...ening torque 150 Nm 111 ft lb Fig 6 Installing circlip Remove circlip arrow with two screwdrivers Page 26 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 287: ...on installed check gear oil in final drive page 39 1 Page 27 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 288: ...l drive gear is riveted onto differential housing and then machined If differential or final drive gear is damaged replace differential housing along with riveted final drive gear Number of teeth on final drive gear from page 00 3 Technical data 2 Output shaft drive flange Removing and installing page 39 23 Page 28 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishe...

Page 289: ...ive out with drift Pressing in Fig 4 5 Bearing body for tapered roller bearing Removing and installing page 39 23 Differential removing and installing 6 O ring Always replace Page 29 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 290: ...al removing and installing 10 Tapered roller bearing outer race Remove and install only when adjusting ring heated Drive out with drift Pressing in Fig 4 11 Tapered roller bearing inner race Pulling off Fig 1 Pressing on Fig 2 Page 30 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS...

Page 291: ... gear Drive out with drift Fit on together with driver bushing item 12 14 One piece thrust washer Place into differential housing before installing bevel gears 15 Small bevel gears Installing Fig 3 16 Large bevel gears Installing Fig 3 17 Circlip Page 31 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT0...

Page 292: ... Spring pin For securing shaft for bevel gears Removing and installing spring pin with circumferential groove Fig 5 Page 32 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 293: ...30 555 on differential housing Fig 2 Pressing on tapered roller bearing inner race Page 33 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 294: ...s offset 180 and swivel in in direction of arrow Fig 4 Pressing in tapered roller bearing outer race With adjusting ring or bearing body heated install outer race and press home as far as stop Page 34 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 295: ...f spring pin 28 5 mm 1 122 in Pull out spring pin with side cutting pliers Drive in spring pin as far as stop Page 35 of 35 Final drive disassembling and assembling 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 3 WWW ALL TRANS BY ProCarManuals com ...

Page 296: ...Determine thickness from table page 39 46 Determine Part No from parts catalog microfiche 5 Shim for drive pinion Determine thickness from table page 39 46 Determine Part No from parts catalog microfiche Page 1 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 4 WWW ALL TRANS BY ProCarManuals com ...

Page 297: ...n Always replace together Re determine correct shim thickness when replacing tapered roller bearings 9 Tapered roller bearings for differential Always replace together Measure friction torque via pinion shaft Friction torque of new tapered roller bearings must be 60 80 Ncm 5 7 in lb greater than friction torque of pinion shaft Page 2 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishe...

Page 298: ...1 Input gear1 page 39 48 Drive pinion with output gear1 page 39 44 Transmission housing X X X Input gear1 X X Input gear tapered roller bearing X Output gear1 X X Drive pinion X Drive pinion tapered roller bearing X Differential housing with gear wheel X Tapered roller bearing for differential bearing body or shim X Supporting ring park lock gear or bearing cover X 1 Always replace input gear and ...

Page 299: ...ge parking lock when performing this step Tightening torque 250 Nm 184 ft lb Note Do not rotate the drive pinion while making this measurement as the bearings will otherwise settle and falsify the result of the measurement Insert dial indicator A and zero gauge with 1 mm preload Moving drive pinion up and down read and record axial play example 0 93 mm Page 4 of 12 Final drive adjusting 12 6 2004 ...

Page 300: ...m Dial indicator reading 0 93 mm Preload 0 12 mm Amount for compression 0 10 mm Thickness of shim 1 85 mm Remove output gear Determine correct shim size from table page 39 46 and install shim on drive pinion Re install output gear tighten hex nut and secure with drift Tightening torque 250 Nm 184 ft lb Page 5 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display...

Page 301: ...1 924 1 925 1 949 1 950 1 974 1 975 1 999 2 000 2 024 2 025 2 049 2 050 2 074 2 075 2 099 2 100 2 124 1 575 1 600 1 625 1 650 1 675 1 700 1 725 1 750 1 775 1 800 1 825 1 850 1 875 1 900 1 925 1 950 1 975 2 000 2 025 2 050 2 075 2 100 2 125 2 125 2 149 2 150 1 274 2 175 2 199 2 200 2 224 2 225 2 249 2 250 2 274 2 275 2 299 2 230 2 324 2 325 2 349 2 350 2 374 2 375 2 399 2 400 2 424 2 425 2 449 2 45...

Page 302: ...cket 41 mm AF Oil bearing beforehand with gear oil Friction torque of new tapered roller bearings must be 80 120 Ncm 7 11 in lb Page 7 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 4 WWW ALL TRANS BY ProCarManuals com ...

Page 303: ...e distance between input gear and tapered roller bearing inner race Insert dial indicator and zero gauge with 3 mm preload Note reading example 1 00 mm The 1 50 mm thickness of the dished washer must be added to the reading 1 00 mm 1 50 mm 2 50 mm Page 8 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 4 WWW ALL TRAN...

Page 304: ...mm Determine shim from table and fit onto drive shaft Table of shims page 39 46 Insert axial needle bearing and tighten socket head fastener including dished washer Tightening torque 250 Nm 184 ft lb Note Insert axial needle bearing for input shaft before tightening socket head fastener Installation position page 39 8 Input gear removing and installing Page 9 of 12 Final drive adjusting 12 6 2004 ...

Page 305: ... A Torque gauge commercially available 0 600 Ncm 0 50 in lb B Socket 41 mm AF Moisten bearings beforehand with ATF Moisten bearings beforehand with ATF Friction torque Drive pinion from measurement 100 Ncm1 Input gear average 200 Ncm Friction torque of input gear drive pinion 300 Ncm Page 10 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type ...

Page 306: ...d secure Tightening torque 150 Nm 111 ft lb Tighten adjusting ring and mark its position Tightening torque 50 Nm 37 ft lb Turn adjusting ring again so it advances the distance of five locking lugs then secure so that preload of tapered roller bearings is set Page 11 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 4 ...

Page 307: ... 0 50 in lb B Socket 41 mm AF Oil bearing beforehand with gear oil Friction torque Drive pinion measurement 300 Ncm1 Differential average 70 Ncm Friction torque of differential drive pinion 370 Ncm Page 12 of 12 Final drive adjusting 12 6 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 AT02 39 4 WWW ALL TRANS BY ProCarManuals com ...

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