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AUTO TRANS DIAGNOSIS - 01M

Article Text (p. 54)

1996 Volkswagen Golf

For Volkswagen Technical Site

Copyright © 1998 Mitchell Repair Information Company, LLC

Thursday, August 19, 1999 11:28PM

Fig. 65: Installing Support Tube
Courtesy of Volkswagen United States, Inc.

Fig. 66: Checking Turbine Shaft End Play
Courtesy of Volkswagen United States, Inc.

Fig. 67: Installing 2nd-4th Brake Clutch Plate & Springs
Courtesy of Volkswagen United States, Inc.

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Содержание 01M

Страница 1: ...Passat 4 Cylinder Gas 4 9 6 3 01M CLK Turbo Diesel 4 9 6 3 01M CKZ V6 4 9 6 3 01M CLB 1 Removal and installation of transmission from vehicle chassis 2 On bench overhaul for transmission and different...

Страница 2: ...t p 2 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 1 Cross Sectional View Of Transaxle Components Court...

Страница 3: ...ctrical Components Courtesy of Volkswagen United States Inc The transmission elements consist of a planetary gear set one way roller clutch 3 apply clutches 2 brake clutches and a torque converter loc...

Страница 4: ...ve and controls the main hydraulic pressure The TCM controls the main hydraulic pressure by varying the duty cycle The TCM monitors input and output signals If electrical problems occur TCM will recor...

Страница 5: ...le Differential Oils Mixed Replace O ring and drive pinion seal on inner bearing support Gear Selector Hard To Move Check gear selector between shifter and transaxle Repair as necessary Check parking...

Страница 6: ...ing Into 1st Gear Faulty Powertrain Control Module PCM Engine Starts In Gear Or No Start In Park Neutral Check for faulty Park Neutral safety switch Shift Lock Not Holding Selector In Park Neutral Che...

Страница 7: ...down shift speeds to kickdown shift speed specifications See KICKDOWN SHIFT SPEED SPECIFICATIONS table NOTE In the following table letter suffix following gear application refers to Hydraulic H or Mec...

Страница 8: ...affected remove valve body Locate appropriate fluid circuit in transaxle case and valve body Check for leaks and or blockage Repair as necessary 6 If hydraulic circuits are okay or problems with appl...

Страница 9: ...ved out of Park position by turning ignition key to START position Functional Check 1 With ignition key removed ensure gear selector cannot be moved from P position Insert key in ignition switch 2 Tur...

Страница 10: ...10 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 4 Exploded View Of Shift Lock Gear Selector Assembly C...

Страница 11: ...019 30 mm feeler gauge between shift lock solenoid push rod and shift lever See Fig 5 If necessary move shift lock solenoid and tighten screws Fig 5 Adjusting Shift Lock Solenoid Courtesy of Volkswag...

Страница 12: ...cover Disconnect negative battery cable and wait 30 seconds 2 Using Torx wrench remove air bag retaining screws from rear side of steering wheel Lift off air bag unit from steering wheel and tilt air...

Страница 13: ...located under rear seat control solenoids and various sensors and switches TCM monitors input and output signals See Fig 2 2 If TCM detects problems in transaxle related circuits or devices TCM may re...

Страница 14: ...y August 19 1999 11 28PM box to TCM vehicle harness Leave TCM disconnected 3 Measure voltage and resistance between specified sockets on test box See Figs 10 13 If a problem is found service harness o...

Страница 15: ...Text p 15 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 11 Testing TCM Harness Components 2 Of 4 Courtes...

Страница 16: ...en Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 12 Testing TCM Harness Components 3 Of 4 Courtesy of Volkswagen United States Inc Fig 13 Te...

Страница 17: ...ctor disconnected After test reconnect solenoid valves and using appropriate scan tool erase trouble codes from memory STALL SPEED CAUTION DO NOT operate engine at stall speed for more than 5 seconds...

Страница 18: ...and installation procedures see TRANSAXLE DISASSEMBLY Drive Flanges External Oil Filter Gear Selector Lever Multifunction Switch Speedometer Drive Shaft Speed Sensor Oil Pan Valve Body Assembly Plane...

Страница 19: ...to side of transaxle case See Fig 19 Loosen and remove small planetary drive shaft bolt washer and shim See Fig 20 Remove small planetary drive shaft 5 Remove large drive shaft and sun gear Remove Veh...

Страница 20: ...For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 15 Checking Turbine Shaft End Play Courtesy of Volkswagen United States Inc Fi...

Страница 21: ...e Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 17 Exploded View Of Transaxle Components Courtesy of Volkswagen United States Inc Fig 18 Removing Turbine S...

Страница 22: ...agen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 19 Locking Small Sun Gear Drive Shell Courtesy of Volkswagen United States Inc Fig 20 Rem...

Страница 23: ...lb torque wrench to a 1 5 8 41 mm socket wrench See Fig 22 Measure and record total roller bearing turning torque of drive pinion gear This measurement is required for reassembly reference if roller...

Страница 24: ...e Using Bearing Adjuster Ring Socket 3155 remove both differential bearing carriers See Fig 24 Remove differential assembly from transaxle case See Fig 23 7 Remove drive pinion and input transfer gear...

Страница 25: ...Text p 25 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 23 Exploded View Of Drive Gear Assembly Courtesy...

Страница 26: ...chnical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 24 Removing Bearing Adjuster Ring Bearing Carrier Courtesy of Volkswagen United States Inc Fig 2...

Страница 27: ...n Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 26 Exploded View Of Drive Pinion Output Gear Assembly Courtesy of Volkswagen United States I...

Страница 28: ...ssemble differential reverse disassembly NOTE If differential bearings are replaced check differential side bearing preload and ring gear position See FINAL DRIVE TRANSFER GEARS under TRANSAXLE REASSE...

Страница 29: ...19 1999 11 28PM OIL PUMP 2ND 4TH BRAKE CLUTCH PISTON Disassemble oil pump and 2nd 4th brake clutch piston Check for worn or damaged parts and replace as necessary Replace all seals and reassemble See...

Страница 30: ...essary Compress each spring and install into cage See Fig 30 2 Hold cage assembly with large lugs up Install cage assembly into outer ring See Figs 31 33 Rotate cage clockwise until lugs touch stop In...

Страница 31: ...rier small sun gear pinion drive transfer gear and all related bearings and washers onto small planetary drive shaft See Figs 17 and 20 3 Place assembly into transaxle case Install adjustment shim was...

Страница 32: ...iction faced clutch plates in ATF for at least 15 minutes before installation 1 Mark circlip for installation reference and remove Disassemble clutch plates See Fig 35 Compress spring support and remo...

Страница 33: ...UTCHES Reverse and 2nd 4th brake clutches are disassembled and reassembled during transaxle disassembly and reassembly See TRANSAXLE DISASSEMBLY and TRANSAXLE REASSEMBLY TRANSAXLE CASE 1 Remove multif...

Страница 34: ...Using a center punch peen parking pawl pin Install operating rod for manual valve detent spring screws multifunction switch and new seals Fig 36 Exploded View Of Transaxle Case Components Courtesy of...

Страница 35: ...from manufacturer 1ST 3RD APPLY CLUTCH 1 Remove support ring Mark circlip for installation reference and remove circlip Disassemble clutch plates See Fig 38 Remove diaphragm spring circlip Compress sp...

Страница 36: ...Text p 36 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 38 Exploded View Of 1st 3rd Apply Clutch Courtes...

Страница 37: ...stall bottom thrust plate with smooth side facing clutch plate Install one inner splined and one outer splined clutch plate into clutch housing See Fig 38 5 Place inner plate carrier on bench Install...

Страница 38: ...nce and remove Disassemble clutch plates See Fig 42 Compress spring support ring and remove circlip Remove spring support ring and spring Remove clutch piston 2 Remove front impeller seal rings DO NOT...

Страница 39: ...e Text p 39 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 42 Exploded View Of 4th Apply Clutch Courtesy...

Страница 40: ...pinion bearing race support Go to next step NOTE Install drive pinion seal with lip opening facing closest roller bearing 2 If reusing drive pinion and large pinion bearing DO NOT remove existing shi...

Страница 41: ...gs Races Adjustment Shims Courtesy of Volkswagen United States Inc Fig 45 Checking Drive Pinion Roller Bearing End Play Courtesy of Volkswagen United States Inc 7 Drive pinion requires 008 220 mm prel...

Страница 42: ...N m to seat bearings 9 Using INCH lb torque wrench rotate torque wrench at least 8 turns to determine turning torque Measure turning torque of drive pinion roller bearings See Fig 46 See DRIVE PINION...

Страница 43: ...between lugs on inner roller bearing See Fig 48 3 Install outer roller bearing without dished washer or shim on input transfer gear See Figs 44 and 47 Engage parking gear Using an Allen head socket t...

Страница 44: ...August 19 1999 11 28PM Fig 48 Aligning Lugs On Input Transfer Gear Roller Bearings Courtesy of Volkswagen United States Inc Fig 49 Tightening Fastener Nut On Input Transfer Gear Roller Bearings Courte...

Страница 45: ...ded during disassembly See FINAL DRIVE TRANSFER GEARS under TRANSAXLE DISASSEMBLY 8 Remove fastener nut If necessary select a shim and recheck roller bearing preload If roller bearing preload is okay...

Страница 46: ...5 7 INCH Lbs 6 8 N m Used Bearings Same As Before Disassembly 1 Recorded during disassembly See FINAL DRIVE TRANSFER GEARS under TRANSAXLE DISASSEMBLY 6 Install circlips to end of each axle See Fig 52...

Страница 47: ...3 Install O ring and planetary carrier Install washer and axial needle bearing into planetary carrier See Figs 25 and 54 Install end plate shim for reverse brake clutch plates See Fig 55 2 Install rev...

Страница 48: ...cal Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 54 Installing Planetary Carrier Axial Needle Bearing Courtesy of Volkswagen United States Inc Fig 55...

Страница 49: ...kswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 56 Installing Reverse Brake Clutch Plates Courtesy of Volkswagen United States Inc Fig...

Страница 50: ...nformation Company LLC Thursday August 19 1999 11 28PM Fig 58 Installing Circlips Courtesy of Volkswagen United States Inc Fig 59 Checking Reverse Brake Clutch Clearance Courtesy of Volkswagen United...

Страница 51: ...small planetary drive shaft with needle bearings See Figs 17 61 and 62 Using a screwdriver lock small sun gear drive shell to large sun gear drive shell See Fig 19 Install adjustment shim washer and b...

Страница 52: ...rposes install oil pump gasket and oil pump See Fig 17 Position dial indicator and Support VW 387 on transaxle case See Fig 66 9 Press dial indicator on turbine shaft and apply 040 1 0 mm preload Move...

Страница 53: ...nical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 63 Installing 4th Apply Clutch Impeller Shaft Courtesy of Volkswagen United States Inc Fig 64 Inst...

Страница 54: ...hell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 65 Installing Support Tube Courtesy of Volkswagen United States Inc Fig 66 Checking Turbine Shaft End Play Courtesy of Volkswage...

Страница 55: ...brake clutch to piston distance 16 Subtract 140 3 6 mm from value calculated in step 15 This determines thickness of last outer splined 2nd 4th brake clutch plate Outer splined 2nd 4th brake clutch p...

Страница 56: ...pyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 69 Measuring Oil Pump Flange To Clutch Plate Courtesy of Volkswagen United States Inc Fig 70 Measuring Height O...

Страница 57: ...lts 33 45 Drive Pinion Bearing O Ring Support 148 200 Drive Pinion Nut 184 250 Input Transfer Gear Nut 184 250 Oil Cooler Banjo Bolts 26 35 Small Planetary Drive Shaft Bolt 22 30 Starter To Transaxle...

Страница 58: ...7 Transaxle may shift erratic harsh or hold shifts too long delayed upshifts with no trouble codes stored in memory This condition is normally caused by improper throttle angle setting If shifting qua...

Страница 59: ...play reads 99 percent DO NOT release pedal resistance of kickdown switch should be felt Print screen 7 Continue pressing accelerator pedal to its stop while observing fourth digit on right side 8 digi...

Страница 60: ...cle Text p 60 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 73 1995 Transaxle Wiring Diagram Cabrio Golf...

Страница 61: ...M Article Text p 61 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 74 1995 Transaxle Wiring Diagram Cabri...

Страница 62: ...Article Text p 62 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 28PM Fig 75 1995 Transaxle Wiring Diagram Golf Je...

Страница 63: ...GNOSIS 01M Article Text p 63 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 29PM Fig 76 1995 Transaxle Wiring Diag...

Страница 64: ...IAGNOSIS 01M Article Text p 64 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 29PM Fig 77 1995 Transaxle Wiring Di...

Страница 65: ...IAGNOSIS 01M Article Text p 65 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 29PM Fig 78 1996 Transaxle Wiring Di...

Страница 66: ...1M Article Text p 66 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 29PM Fig 79 1996 Transaxle Wiring Diagram Golf...

Страница 67: ...01M Article Text p 67 1996 Volkswagen Golf For Volkswagen Technical Site Copyright 1998 Mitchell Repair Information Company LLC Thursday August 19 1999 11 29PM Fig 80 1996 Transaxle Wiring Diagram Pa...

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