At 096 Overhaul

AUTO TRANS OVERHAUL - 096Article Text

1991 Volkswagen PassatThis file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

AUTOMATIC TRANSMISSIONS Volkswagen Model 096

Corrado SLC, Golf, Golf III, Jetta, Jetta III, Passat

APPLICATION & LABOR TIMES

APPLICATION & LABOR TIMESÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄVehicle Labor Times Trans.Application (1) R & I (2) Overhaul Model

1990 Passat .................. 4.9 ....... 6.3 ..... 096 (APE)

1991-93 (Up To 12/92) Corrado SLC ............. 4.9 ....... 6.3 ..... 096 (CFA) Golf & Jetta 4-Cylinder ............ 4.4 ....... 6.3 ..... 096 (CFC) V6 .................... 4.4 ....... 6.3 ..... 096 (CFA) Passat .................. 4.9 ....... 6.3 ..... 096 (APE)

1993 (From 1/93) Corrado SLC ............. 4.9 ....... 6.3 ..... 096 (CFF) Golf, Jetta & Passat 4-Cylinder ............ 4.4 ....... 6.3 ..... 096 (CFH) V6 (Golf & Jetta) ..... 4.9 ....... 6.3 .. (3) 096 (CFF)

1994 Corrado SLC ............. 4.9 ....... 6.3 ..... 096 (CFF) Golf, Jetta & Passat 4-Cylinder ............ 4.4 ....... 6.3 ..... 096 (CNK) V6 .................... 4.9 ....... 6.3 ..... 096 (CFF) Jetta GLX ............... 4.9 ....... 6.3 ..... 096 (CFF)

(1) - Removal and installation of transmission from vehicle chassis.(2) - On bench overhaul for transmission and differential. DOES NOT include removal and installation.(3) - Used on Golf and Jetta only.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

IDENTIFICATION

Transaxle type is cast into transaxle case above left outputshaft flange. Transaxle code and build date are located on front topof transaxle case.

DESCRIPTION & OPERATION

This transaxle includes a 4-speed automatic transmission, atorque converter, a final drive and solenoid-operated valve body. SeeFig. 1. Under normal conditions, all shifts are controlled by aTransaxle Control Module (TCM). See Fig. 10. Fourth gear is anoverdrive gear.

NOTE: TCM may also be referred to as the Transaxle Control Unit (TCU).

NOTE: Transaxle uses a standard torque converter (with internal damper plate). * On 1991 to early 1993 transaxles, the power flow in third gear changes depending on driving conditions. During 3rd gear (non-TCM controlled) and 4th gear operation, the 3rd-4th apply clutch is engaged. This locks the impeller shaft and small planetary drive shaft together, creating a direct coupling between the engine and transaxle. Overdrive (4th gear) is engaged by the 3rd-4th apply clutch and 2nd-4th brake clutch. During 3rd gear operation (TCM controlled), the transaxle engages 1st-3rd apply clutch and reverse clutch. This engages the turbine shaft to the large planetary drive shaft (through the 1st-3rd and reverse apply clutches), activating the torque converter. * On late 1993 and 1994 transaxles, 3rd gear power flow occurs through 1st-3rd apply clutch and reverse gear clutch. Overdrive (4th gear) is engaged by the 3rd-4th apply clutch and 2nd-4th brake clutch.

Fig. 1: Cross-Sectional View Of Transaxle ComponentsCourtesy of Volkswagen United States, Inc.

Fig. 2: View Of Transmission Clutches, Shafts & Planetary AssembliesCourtesy of Volkswagen United States, Inc.

The transmission elements consist of a planetary gear set,one-way roller clutch, 3 apply clutches and 2 brake clutches. Refer tothe Fig. 2. Power from the transmission is connected to the drivepinion through transfer gears. A ring gear and differential assemblyare connected to flanges which spin the drive axles. The electronic control consists of a TCM (located underright front floor on 1991 to early 1993 models or under rear seat onlate 1993 and 1994 models), control solenoids, various sensors andswitches. The control solenoids direct oil pressure inside the valvebody. Solenoid valves No. 1-4 control the apply and brake clutches.Solenoid valves No. 5 and 7 control shift smootheness. Control solenoid valve No. 6 is a frequency valve andcontrols the main hydraulic pressure. The TCM controls the mainhydraulic pressure by varying the duty cycle. On 1991 to early 1993 models, an ECO/SPORT button (located ongear selector console) changes the shift program. When the ECO/SPORTbutton is pressed (sport mode), this signals the TCM to change theshift program. On late 1993 and 1994 models, the ECO/SPORT switch isdeleted. The TCM monitors input and output signals. If electricalproblems occur, TCM will record faults in TCM memory and may go intofail-safe mode. If TCM enters fail-safe mode, the transaxle willoperate manually in reverse, 1st or 3rd gear. In fail-safe mode, 3rdgear operates with gear selector in 2nd, 3rd or "D". The TCM memorycan only be read on Tester (VAG 1551/1).

The TCM also controls shift lock system. This system locksthe gear selector in Park or Neutral unless the brake pedal is pusheddown. The TCM uses a shift lock control relay to release a gear-selector mounted solenoid.

LUBRICATION & ADJUSTMENTS

See the TRANSMISSION SERVICING - A/T article in the AUTOMATICTRANS SERVICING section. Refer to the following menu:

* Corrado & Passat, see: TRANSMISSION SERVICING - A/T

* Golf & Jetta, see: TRANSMISSION SERVICING - A/T

TROUBLE SHOOTING

SYMPTOM DIAGNOSIS

Leak At Torque Converter Check drive plate clearance, torque converter bushing, oilseal or oil pump assembly. Repair as necessary.

Transaxle Fluid in Coolant Faulty transaxle oil cooler. Replace transaxle oil cooler andfriction plates in transaxle. Clean transaxle.

Transaxle & Differential Oils Mixed Replace "O" ring and drive pinion seal on inner bearingsupport.

Gear Selector Hard To Move Check gear selector between shifter and transaxle. Repair asnecessary. Check parking lock assembly inside transaxle. Repair asnecessary.

No Drive In 1st Gear Check for faulty 1st-3rd apply clutch or reverse brakeclutch.

No Drive In "D", "2" Or "3" Check for faulty 1st-3rd apply clutch or one-way clutch.

No 2nd Gear In "D", "2" Or "3" Check for faulty 2nd-4th brake clutch.

No 3rd Gear In "D" Or "3" Check for faulty reverse apply clutch.

No 4th Gear In "D" (1991 to Early 1993 Only) Check for faulty 4th gear and 2nd-4th brake clutch.

No 4th Gear In "D" (Late 1993-94)

Check for faulty 2nd-4th brake clutch.

No Reverse Check for faulty reverse apply clutch or reverse brakeclutch.

No Drive In All Forward Gear Positions Check for faulty 1st-3rd apply clutch, reverse brake clutchor one-way clutch.

Missing Shifts Up Or Down Check valve body for sticking valve(s) or faulty shiftsolenoid(s).

Erratic Or Harsh Shifts Short in wiring to shift solenoid(s) or faulty shiftsolenoid(s).

Harsh Shift In One Gear Only Determine elements involved. Air check elements. Check forfaulty shift solenoid or shift valve.

Stuck In Emergency Running Mode Check for incorrect TCM installed, faulty wiring, badsolenoid electrical strip (inside oil pan) or stuck valve.

Park Lock Will Not Engage Check for misadjusted selector lever cable. Check for faultylocking mechanism.

Bucking Or Poor Idling Check throttle housing and air ducts of leaks. Check forpossible air entering oil pump pickup.

Excess Engine RPM Drop When Shifting Into 1st Gear Faulty Engine Control Module (ECM).

Engine Starts In Gear Or No Start In Park/Neutral Check for faulty Park/Neutral saftey switch.

Shift-Lock Not Holding Selector In Park/Neutral Check for faulty shift lock solenoid, shift lock mechanism orbad TCM.

ECO/SPORT Malfunction Check for faulty switch, related wiring or connections.

MECHANICAL, HYDRAULIC & ELECTRICAL COMPONENTS

1) If gear selector is stuck in Park or Neutral, proceed toSHIFT LOCK SYSTEM under TROUBLE SHOOTING. If gear positions aremissing, shift quality is poor or no shifts are possible, ensure allelectrical connections are okay and fluid level is correct.

2) If problems are still present, disconnect electricalconnector at transaxle. Test drive vehicle. Check if transaxle willoperate manually in reverse and 1st gear. Move gear selector to 2nd,3rd or "D" position. Transaxle should operate in 3rd gear (2nd, 3rd or"D"). 3) If transaxle operates as described, problem may beelectrical. Refer to ELECTRONIC SELF-DIAGNOSTICS. If transaxle doesnot operate as described, problem may be mechanical or hydraulic. SeeROAD TEST.

NOTE: If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear.

ROAD TEST

WARNING: DO NOT exceed safe or legal speed limits during road test.

1) Road test vehicle. Move ECO/SPORT switch (if equipped) toECO. From a stop, perform full throttle upshifts with transaxle in"D". Note upshift speeds. 2) With vehicle at a speed above kickdown speed, press thethrottle pedal down and note kickdown shift speeds. Repeat the roadtest with the ECO/SPORT switch (if equipped) in the SPORT position.Compare vehicle shift speeds to the shift speed specifications in theSHIFT SPEED SPECIFICATIONS table.

SHIFT SPEED SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Full Throttle KickdownApplication (MPH) (MPH)

1991-to-Early 1993 Models 4-Cylinder ECO Mode 1-2 .................... 18-21 ............. 28-31 2-3 .................... 36-40 ............. 53-56 3-3 (1) ................ 53-56 ............. 76-80 3-4 .................... 78-82 ............. 89-93 4-3 .................... 54-51 ............. 89-85 3-3 (2) ................ 32-36 ............. 51-48 3-2 .................... 32-28 ............. 51-48 2-1 ..................... 8-4 .............. 28-24 SPORT Mode 1-2 .................... 28-31 ............. 28-31 2-3 .................... 53-56 ............. 56-53 3-3 (1) ................ 76-80 ............. 76-80 3-4 .................... 89-93 ............. 89-93 4-3 .................... 77-73 ............. 89-85 3-3 (2) ................ 39-36 ............. 51-48

3-2 .................... 32-28 ............. 51-48 2-1 .................... 18-14 ............. 28-24

V6 ECO Mode 1-2 .................... 19-23 ............. 33-36 2-3 .................... 41-44 ............. 58-61 3-3 (1) ................ 58-61 ............. 83-87 3-4 .................... 79-83 ............ 98-101 4-3 .................... 61-64 ............. 97-93 3-3 (2) ................ 34-30 ............. 57-53 3-2 .................... 32-28 ............. 57-53 2-1 .................... 10-6 .............. 29-25 SPORT Mode 1-2 .................... 33-36 ............. 33-36 2-3 .................... 58-61 ............. 58-61 3-3 (1) ................ 83-87 ............. 83-87 3-4 ................... 98-101 ............ 89-101 4-3 .................... 83-78 ............. 97-93 3-3 (2) ................ 38-34 ............. 57-53 3-2 .................... 32-28 ............. 57-53 2-1 .................... 19-15 ............. 29-25

Late 1993 & 1994 Models 4-Cylinder 1-2 ...................... ... .............. 32-35 2-3 ...................... ... .............. 62-66 3-4 ...................... ... .............. 89-95 4-3 ...................... ... .............. 91-87 3-2 ...................... ... .............. 61-57 2-1 ...................... ... .............. 29-25 V6 1-2 ...................... ... .............. 38-42 2-3 ...................... ... .............. 76-80 3-4 ...................... ... ............ 109-113 4-3 ...................... ... ............ 111-107 3-2 ...................... ... .............. 74-70 2-1 ...................... ... .............. 31-27

(1) - Transaxle shifts to TCM-controlled operation.(2) - Transaxle shifts from TCM-controlled to non-TCM controlled operation.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

3) If transaxle does not shift within specified MPH range,determine affected elements. See APPLY & BRAKE CLUTCH APPLICATION. 4) If all apply and brake clutch elements are affected, checkoil pump, oil filter, cooler lines, solenoid valve No. 6, operation ofECO/SPORT switch (if equipped), condition of torque converter and/orengine. Repair as necessary. 5) If one or more apply and brake clutch elements areaffected, remove valve body. Locate appropriate fluid circuit in

transaxle case and valve body. See Figs. 3-10. Check for leaks andblockage. Repair as necessary. 6) If hydraulic circuits are okay or problems with apply andbrake clutch elements are mechanical, repair transaxle.

NOTE: If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear.

APPLY & BRAKE CLUTCH APPLICATION

APPLY & BRAKE CLUTCH APPLICATION (1991-TO-EARLY 1993)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄGear Selector Position Elements In Use

"D" (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake 3rd Gear (1) .......... 1st-3rd & Reverse Apply Clutches 4th Gear ................. 3rd-4th Apply & 2nd-4th Brake

3rd (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake 3rd Gear (1) .......... 1st-3rd & 3rd-4th Apply Clutches

3rd (Manual) 3rd Gear (2) .... 1st-3rd Apply, 3rd-4th & Reverse Apply

2nd (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake

1st (Manual) 1st Gear ................. 1st-3rd Apply & Reverse Brake

Reverse .................... Reverse Apply & Reverse BrakePark & Neutral ................ All Apply & Brake Clutches Released Or Ineffective

(1) - 1st-3rd and reverse apply clutches are engaged. However, main power path is the 3rd-4th apply clutch.(2) - These elements are in use during TCM fail-safe mode.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

APPLY & BRAKE CLUTCH APPLICATION (LATE 1993-94)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄGear Selector Position Elements In Use

"D" (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding

2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake 3rd Gear (1) .......... 1st-3rd & Reverse Apply Clutches 4th Gear ................. 3rd-4th Apply & 2nd-4th Brake

3rd (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake 3rd Gear .............. 1st-3rd & Reverse Apply Clutches

2nd (Drive) 1st Gear ........ 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................. 1st-3rd Apply & 2nd-4th Brake

1st (Manual) 1st Gear ................. 1st-3rd Apply & Reverse Brake

Reverse .................... Reverse Apply & Reverse Brake

Park & Neutral ................ All Apply & Brake Clutches Released Or IneffectiveÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

VALVE BODY OIL CIRCUITS

Fig. 3: Reverse Gear Valve Body Oil CircuitsCourtesy of Volkswagen United States, Inc.

Fig. 4: 1st (In "D") Gear Valve Body Oil CircuitsCourtesy of Volkswagen United States, Inc.

Fig. 5: 1st (In Manual 1st) Gear Valve Body Oil CircuitsCourtesy of Volkswagen United States, Inc.

Fig. 6: 2nd Gear Valve Body Oil Circuits

Courtesy of Volkswagen United States, Inc.

Fig. 7: 3rd (In "D") Gear Valve Body Oil CircuitsCourtesy of Volkswagen United States, Inc.

Fig. 8: 3rd (In Manual) Gear Valve Body Oil CircuitsCourtesy of Volkswagen United States, Inc.

Fig. 9: 4th Gear Valve Body Oil Circuits


SHIFT LOCK SYSTEM

Operation All models are equipped with an electronic shift lock system.TCM controls shift lock system. See Fig. 10. This system locks gearselector in Park or Neutral position unless brake pedal is pusheddown. TCM uses shift lock control relay to release a solenoid mountedon gear selector assembly.

NOTE: Shift lock relay will not lock gear selector when vehicle speed is greater than 3 MPH.

A mechanical control cable prevents ignition key from beingremoved unless gear selector is in Park. With ignition key removed,gear selector locks in Park.

NOTE: If battery is disconnected or discharged, gear selector can be moved out of Park by turning ignition key to START position.

Fig. 10: Identifying TCM & Shift Lock Electrical Components


Functional Check 1) With ignition key removed, ensure gear selector cannot be

moved from Park. Insert key in ignition switch. 2) Turn ignition switch on. Ensure gear selector can only bemoved with brake pedal pressed down. Move gear selector to Neutralposition. 3) Without pressing brake pedal, ensure gear selector cannotmove out of Neutral. Press brake pedal down. Ensure it is now possibleto move gear selector. 4) If shift lock system does not operate as described, adjustgear selector, solenoid and control cable. If shift lock system doesnot operate after adjustments are made, check electrical system ofshift lock system with Tester (VAG 1551/1). 5) See testing information under ELECTRONIC SELF-DIAGNOSTICS.See Figs. 17-21. If any problems are found, service harness orcomponents. If no problems are found, TCM may be defective. If shiftlock system still does not operate correctly, check for worn ordamaged parts and replace as necessary. See Figs. 10 and 11.

Fig. 11: Exploded View Of Shift Lock & Gear Selector AssemblyCourtesy of Volkswagen United States, Inc.

NOTE: Perform the following adjustments in order given.

Adjustment (Control Cable) Loosen lock screw at gear selector lever on transaxle. Movegear selector in center console to Park position. Ensure front wheelsare locked. Tighten cable housing to gear selector lever lock screw.

Adjustment (Shift Lock Solenoid) Place gear selector in Neutral or Park. Loosen shift locksolenoid mounting screws. Insert a .019" (.30 mm) feeler gauge betweenshift lock solenoid push rod and shift lever. See Fig. 12. Ifnecessary, move shift lock solenoid and tighten screws.

Fig. 12: Adjusting Shift-Lock SolenoidCourtesy of Volkswagen United States, Inc.

Adjustment (Shift Lock Cable) 1) Move gear selector to "1" position. Remove steering columncovers. Turn ignition key to Start position and release. Checkclearance between shift lock cable lever and ignition switch lockingpin. 2) Clearance should be .028" (.70 mm). If clearance is notcorrect, lock nut on shift lock cable sheath. Position shift lockcable lever to obtain correct clearance. Tighten lock nut. Refer tothe Fig. 13. Tighten gear selector housing screws and install steeringcolumn covers.

Fig. 13: Adjusting Shift Lock CableCourtesy of Volkswagen United States, Inc.

Removal & Installation (Control Cable) Remove cover from center console. Remove circlip from controlcable end. Remove exhaust covers. On V6 engines, remove catalyticconverter. On all engines, loosen lock nut and remove control cablefrom shift lever on transaxle. To install, reverse installationprocedure and adjust control cable.

Removal & Installation (Shift Lock Cable) 1) Remove shift lever handle. Remove center console cover.Disconnect negative battery cable and wait 30 seconds. 2) Using Torx wrench, remove air bag retaining screws fromrear side of steering wheel. Lift off air bag unit from steeringwheel, and tilt air bag unit downward. Disconnect wiring connectorfrom air bag unit. Remove steering wheel. Remove dash panel. 3) Place gear selector in rear position. Loosen screw hldingcable sheath to gear selector support. Remove cable from lever. SeeFig. 14. 4) Remove cover from ignition switch. Remove spring clipholding cable housing to ignition assembly. Lift and tilt shift lockcable housing upward. Pull up shift lock cable until shift lock cableunhooks from ignition switch. See Fig. 15.

Fig. 14: Removing Shift Lock Cable From Shift Lever SupportCourtesy of Volkwagen United States, Inc.

Fig. 15: Removing Shift Lock Cable From Ignition SwitchCourtesy of Volkwagen United States, Inc.

5) Remove shift-lock cable from under dash near A/C-heaterhousing and remove from vehicle. To install, position shift lock cablethrough under-dash panels. See Fig. 16. Reverse removal procedure tocomplete installation. Adjust shift lock control cable. Refer toADJUSTMENT (SHIFT LOCK CABLE) procedure under SHIFT LOCK SYSTEM.

Fig. 16: Routing Shift Lock Cable To Ignition SwitchCourtesy of Volkwagen United States, Inc.

ELECTRONIC SELF-DIAGNOSTICS

1) Electronic control consists of a TCM (under right frontfootwell or rear seat), control solenoids, and various sensors andswitches. TCM monitors input and output signals. See Fig. 10. 2) If TCM detects problems in transaxle-related circuits ordevices, TCM may record a trouble code in memory. To obtain troublecodes, use VAG Tester (1551/1) adapters and back probe harness. Alltrouble code and related testing information are contained in tester. 3) If tester is not available, turn ignition off anddisconnect battery. Disconnect TCM harness connector. On 38-pin TCMconnectors, install back-probe harness and adapter between TCM and TCMharness. On 68-pin TCM connectors, install Back-Probe Test Box (VAG1598/18) to TCM and TCM harness. 4) Measure voltage and resistance between specified terminalsof TCM connector. See Figs. 17-24. If problem is found, serviceharness or components. If no problem is found, TCM may be defective.

AUTO TRANS OVERHAUL - 096 Article Text (p. 18)

Fig. 17: Testing 38-Pin TCM Harness & Components (1 Of 8)




















TESTING

ELECTRICAL

1) Manufacturer does not provide electrical component testsor specifications. All testing information is contained in Tester (VAG1551/1). 2) If Tester (VAG 1551/1) is not available, turn ignition offand disconnect battery. Disconnect TCM harness connector. InstallBack-Probe Harness (VAG 1598) between TCM and TCM harness. 3) Measure voltage and resistance between specified terminalsof TCM connector. See Figs. 17-24. If any problems are found, serviceharness or components. If no problems are found, TCM may be defective.

HYDRAULIC PRESSURE

Check operation of apply and brake clutches by air checkingfluid passages of valve body and transaxle case. See Figs. 3-9.Install Pressure Gauge (VAG 1702) to transaxle pressure tap locatednear dipstick tube. Check main hydraulic pressure under normal driving

conditions. See the MAIN PRESSURE table. If main hydraulic pressuresare not correct, check for excess idle speed, problem with pump orsticking valves in valve body. Repair as necessary.

MAIN PRESSUREÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication psi (Bar)

"D" Idle RPM ............................... 49-55 (3.4-3.8) 2000 RPM (1) ....................... 146-164 (10.1-11.3)

"R" Idle RPM .............................. 94-109 (6.5-7.5) 2000 RPM (1) ....................... 334-348 (23.0-24.0)

(1) - With solenoid valve connector disconnected. After test, reconnect solenoid valves and using appropriate scan tool, erase trouble codes from memory.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

STALL SPEED

1) Engage parking brake and block drive wheels. Connecttachometer to engine. Warm engine to operating temperature. 2) Firmly depress brake pedal. Move gear selector to "D".Open throttle to wide open throttle position. Note engine speed andrelease throttle pedal.

CAUTION: DO NOT operate engine at stall speed for more than 5 seconds. If you need to repeat stall speed test, wait 20 seconds.

3) Compare measured stall speed with stall speedspecification. See STALL SPEED SPECIFICATIONS table. If stall speed iswithin range, test is complete. 4) If stall speed is too low, check engine condition andadjustments. If no problems with engine are found, torque convertermay be defective. If stall speed is too high, check 1st-3rd applyclutch or one-way clutch for slipping or damage.

STALL SPEED SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication RPM

APE ............................. 2750-2950CFA ............................. 2400-2700CFC ............................. 2700-3000CFF ............................. 2350-3050CFH & CNK ....................... 2750-3050ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

ON-VEHICLE SERVICE

DRIVE AXLE SHAFTS

See appropriate AXLE SHAFTS article in the DRIVE AXLESsection. Refer to the following menu:

* Corrado & Passat, see: AXLE SHAFTS

* Golf & Jetta, see: AXLE SHAFTS

OIL COOLER FLUSHING

1) Remove external oil filter. Remove oil lines and allowfluid to drain. Using pressurized solvent, flush remaining fluid anddebris from oil lines and cooler. Repeat flushing if necessary. 2) Use pressurized shop air to remove solvent from oil linesand oil cooler. Install a new external oil filter.

TRANSAXLE COMPONENTS

The following components may be serviced with the transaxlein the vehicle. For removal and installation procedures, refer toTRANSAXLE DISASSEMBLY.

* Drive Flanges * External Oil Filter * Gear Selector Lever * Multifunction Switch, Speedometer Drive Shaft & Speed Sensor * Oil Pan & Valve Body Assembly * Planetary Gear Cover

REMOVAL & INSTALLATION

See the appropriate TRANSMISSION REMOVAL & INSTALLATION - A/Tarticle in the AUTOMATIC TRANS SERVICING section. Refer to thefollowing menu:

* Corrado & Passat: TRANSMISSION REMOVAL & INSTALLATION - A/T

* Golf & Jetta: TRANSMISSION REMOVAL & INSTALLATION - A/T

TORQUE CONVERTER

1) Remove torque converter. Check torque converter for anywear or damage, and replace if necessary. If torque converter is beingreused, drain old fluid. 2) Slightly tilt torque converter on bench. Place a .53-gallon (2.0L) plastic bottle below torque converter. 3) Create a small round hole in bottle cap. Ensure outsidediameter of a small hose fits tightly in bottle cap. Insert hose intobottle cap, and install cap and hose on bottle.

4) Squeeze bottle and place other end of hose into torqueconverter. Release bottle and allow fluid to drain in bottle. Loosenbottle cap, and allow remaining fluid to siphon into bottle.

TRANSAXLE DISASSEMBLY

TRANSMISSION ASSEMBLY

1) Remove torque converter. Remove oil pan and valve bodyassembly. Remove sealing plug from transaxle case. See Figs. 25 and27. 2) Measure and record turbine shaft end play. See Fig. 26.Remove oil pump bolts. Using two M8 bolts, remove oil pump from frontof transaxle. See Fig. 29. 3) Remove turbine shaft complete with 2nd-4th brake clutch,support tube, 1st-3rd and reverse apply clutch assemblies. Removeimpeller shaft and 3rd-4th apply clutch assembly. See Figs. 28 and 30. 4) Remove planetary cover from transaxle case. Engage parkinggear. Using a screwdriver, lock small sun gear drive shell to largesun gear drive shell. See Fig. 31. Remove bolt from end of smallplanetary drive shaft, and remove shaft. 5) Remove small sun gear drive shell, large sun gear driveshell, circlips and one-way clutch. Remove planetary carrier andbearing assembly. Remove reverse brake clutch assembly. Refer to theFigs. 28 and 33. DO NOT remove input gear assembly, unless bearing orgear damage is present. See Fig. 33.

Fig. 25: Locating Sealing PlugCourtesy of Volkswagen United States, Inc.


Fig. 26: Checking Turbine Shaft End PlayCourtesy of Volkswagen United States, Inc.

Fig. 27: Exploded View Of Oil Pan & Valve BodyCourtesy of Volkswagen United States, Inc.

Fig. 28: Exploded View Of Transmission Components (097 Is Shown As

Example; 096 Is Similar)Courtesy of Volkswagen United States, Inc.

Fig. 29: Removing Oil PumpCourtesy of Volkswagen United States, Inc.

Fig. 30: Removing Turbine Shaft With 2nd-4th Brake Clutch

& 1st-3rd Apply ClutchCourtesy of Volkswagen United States, Inc.

Fig. 31: Locking Small Sun Gear Drive ShellCourtesy of Volkswagen United States, Inc.

Fig. 32: Removing Planetary Carrier & Reverse Brake ClutchCourtesy of Volkswagen United States, Inc.

Fig. 33: Locating Planetary & Input Gear AssemblyCourtesy of Volkswagen United States, Inc.

FINAL DRIVE & TRANSFER GEARS

1) Drain gear oil. Attach INCH-lb. torque wrench to a 1 5/8"(41 mm) socket wrench. See Fig. 79. Measure and record total rollerbearing turning torque of drive pinion gear. This measurement isrequired if roller bearings are reused. 2) Engage parking pawl. Using a 7/8" (22 mm) Allen wrenchsocket, remove fastener nut. See Fig. 35. Remove dished washer,bearing and shim. 3) Install fastener nut. Using Pressing Adapter (VW771),thread tool until 1/8" clearance is present between bearing race andfastener nut. 4) Pull input gear out until it bottoms in pressing adapter.Remove pressing adapter. Remove input transfer gear assembly fromtransaxle case. 5) Remove speedometer drive shaft. See Fig. 34. On left axleflange, remove bolt and remove axle flange. On right axle flange,remove circlip. Using puller, remove right axle flange. 6) Remove differential ring gear cover. If bearings are beingreused, mark differential adjuster ring (torque converter side)bearing carrier to transaxle case. Using Bearing Adjuster Ring Socket(3155), remove both differential bearing carriers. See Fig. 36. Removedifferential assembly from transaxle case. See Fig. 34.

NOTE: Differential bearing carrier on left (torque convrerter)

side is tightened to 111 ft. lbs. (150 N.m).

7) Remove drive pinion and input transfer gear cover (if notalready removed). See Fig. 33. Using INCH-lb. torque wrench, measureturning force of drive pinion and transfer gear bearings. Recordmeasurement for reassembly. 8) Engage parking pawl. Remove nut from pinion. Refer to theFigs. 37 and 38. Using puller, remove output gear. Remove selectorshaft and parking pawl assembly. See Fig. 48. Remove outer bearingsupport. Remove parking gear from pinion. Remove pinion and bearingfrom transaxle. Using pin socket, remove inner bearing support withdrive pinion seal.

Fig. 34: Exploded View Of Drive Gear AssemblyCourtesy of Audi of America, Inc.


Fig. 35: Removing Input Transfer Gear Fastener Nut(097 Is Shown As Example; 096 Is Similar)Courtesy of Audi of America, Inc.

Fig. 36: Removing Bearing Adjuster Ring Bearing CarrierCourtesy of Volkswagen United States, Inc.

Fig. 37: Exploded View Of Drive Pinion & Output Gear AssemblyCourtesy of Volkswagen United States, Inc.

Fig. 38: Removing Pinion Drive GearCourtesy of Volkswagen United States, Inc.

COMPONENT DISASSEMBLY & REASSEMBLY

FINAL DRIVE

1) Disassemble differential. See Fig. 39. If ring gear ordifferential housing is damaged, replace differential housing. Toreassemble 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 REASSEMBLY.

2) Using puller, remove roller bearing from differential

housing. Remove speedometer drive gear and bushing. 3) Check all bearing races in adjuster rings and replace ifnecessary. Using hydraulic press, replace bearing race(s). Replaceeach roller bearing and race as a set.

Fig. 39: Exploded View Of DifferentialCourtesy of Volkswagen United States, Inc.

OIL PUMP & 2ND-4TH BRAKE CLUTCH PISTON

Disassemble oil pump and 2nd-4th brake clutch piston. Checkfor worn or damaged parts and replace as necessary. Replace all sealsand reassemble. See Fig. 40.

NOTE: Specifications are not available from manufacturer.


Fig. 40: Exploded View Of Oil Pump & 2nd-4th Brake Clutch PistonCourtesy of Audi of America, Inc.

ONE-WAY CLUTCH

1) Disassemble one-way clutch. Check for worn or damagedparts and replace as necessary. Compress each spring and install intocage. See Fig. 41. 2) Hold cage assembly with large lugs up. Install cageassembly into outer ring. See Figs. 42-44. Rotate cage clockwise untillugs touch stop. Install piston into outer ring.

AUTO TRANS OVERHAUL - 096Article Text (p. 37)1991 Volkswagen PassatFor Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548

Fig. 41: Installing Springs Into Cage

Courtesy of Audi of America, Inc.

Fig. 42: Installing Cage Assembly Into Outer RingCourtesy of Audi of America, Inc.

Fig. 43: Checking One-Way Clutch Rotation

Courtesy of Audi of America, Inc.

Fig. 44: Installing Piston Into One-Way ClutchCourtesy of Audi of America, Inc.

PLANETARY CARRIER

NOTE: Disassembly and reassembly procedures are not available from manufacturer.

Inspection & Adjustment 1) Inspect planetary carrier, pinion gears, sun gears andrelated parts for wear or damage. Replace parts as necessary. 2) Assemble sun gear drive shells, planetary carrier, smallsun gear, pinion drive transfer gear and all related bearings andwashers onto small planetary drive shaft. See Fig. 45. 3) Place assembly into transaxle case. Install adjustmentshim, washer and bolt to pinion drive transfer gear end of smallplanetary drive shaft. Using a screwdriver, lock small sun gear driveshell to large sun gear drive shell. See Fig. 31. Tighten bolt to 22ft. lbs. (30 N.m). 4) Place Dial Indicator Support (VW 382/7) on top ofassembly. See Fig. 46. Measure end play of small sun gear drive shaft. 5) If end play is not .009-.014 (.23-.37 mm), replaceadjustment shim. Adjustment shims range in thickness from .040" (1.00mm) to .114" (2.90 mm) in .004" (.10 mm) increments.

Fig. 45: Locating Planetary Carrier ElementsCourtesy of Volkswagen United States, Inc.

Fig. 46: Adjusting Planetary Carrier End PlayCourtesy of Volkswagen United States, Inc.

APPLY CLUTCH PLATE APPLICATIONS

APPLY CLUTCH PLATE APPLICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Number Of Plates

Reverse Clutch Inner ................................. 5 Outer ................................. 5

1st-3rd Clutch 1991-to-Early 1993 Inner ............................... 5

Outer ............................... 4 Late 1993-94 Inner ............................... 5 Outer ............................... 5

3rd-4th Clutch Inner ................................ 5 Outer 1991-to-Early 1993 ................. 4 Late 1993 & 1994 ................... 5ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

REVERSE APPLY CLUTCH

NOTE: Soak all friction-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. 47. Compress spring support, andremove circlip. Remove clutch piston. 2) Check for worn or damaged parts and replace as necessary.Ensure check ball in clutch housing is not damaged. Piston seal ispart of piston. If damaged, replace reverse apply clutch piston.Reassemble reverse apply clutch. See APPLY CLUTCH PLATE APPLICATIONStable.

NOTE: Assembled clutch clearance specification is not available from manufacturer. Ensure thrust plate is installed with shouldered side facing circlip.

Fig. 47: Exploded View Of Reverse Apply ClutchCourtesy of Audi of America, Inc.

REVERSE & 2ND-4TH BRAKE CLUTCHES

Reverse and 2nd-4th brake clutches are disassembled andreassembled at disassembly and reassembly. See TRANSAXLE DISASSEMBLYand TRANSAXLE REASSEMBLY.

TRANSAXLE CASE

1) Remove multifunction switch, all seals, manual valveassembly, parking pawl and sensors. If necessary, remove parking pawlpin, detent spring screws and selector rod for manual valve from case.See Fig. 48. Inspect bushings and bearing races, and replace ifnecessary. 2) Install new "O" ring to gear change shaft. Install gearchange shaft. Install parking pawl pin (if removed). Using a centerpunch, peen parking pawl pin. Install operating rod for manual valve,detent spring screws, multifunction switch and new seals.

Fig. 48: Exploded View Of Transaxle Case ComponentsCourtesy of Volkswagen United States, Inc.

TRANSFER GEARS

Using puller and adapter, remove tapered bearing from outputgear. See Fig. 49. Using hydraulic press, install bearing to drivepinion transfer gear. Set transfer and drive pinion gears aside.

Fig. 49: Removing Output Gear Roller BearingCourtesy of Volkswagen United States, Inc.

VALVE BODY

NOTE: Disassembly and reassembly procedures are not available from manufacturer.

1ST & 3RD APPLY CLUTCH


1) Remove support ring. Mark circlip for installationreference, and remove circlip. Disassemble clutch plates. SeeFig. 50. Remove diaphragm spring circlip. Compress spring support, andremove circlip. See Fig. 51. Remove spring plates and clutch piston. 2) Remove piston rings from piston. Piston seal is part ofpiston. If damaged, replace 1st-3rd apply clutch piston. Remove sealrings from turbine shaft. Check for worn or damaged parts and replaceas necessary. Ensure check ball in clutch housing is not damaged.

Fig. 50: Exploded View Of 1st-3rd Apply Clutch(1991-to-Early 1993 Is Shown; Late 1993-94 Is Similar)Courtesy of Volkswagen United States, Inc.

Fig. 51: Removing & Installing Spring CirclipCourtesy of Volkswagen United States, Inc.

3) Install new seal rings to clutch piston, and installpiston in clutch housing. Install plate springs with curved sidesfacing piston. Install operating ring with curved side facing springs.Compress spring support and install circlip. See Fig. 50. 4) On 1991-to-early 1993 models, install diaphragm springwith curved side facing piston. Install circlip. See Fig. 52. On allmodel years, install bottom thrust plate with smooth side facingclutch plate. Install one inner splined and one outer splined clutchplate into clutch housing. See Fig. 51. 5) Place inner plate carrier on bench. Install remainingclutch plates to inner plate carrier. See the APPLY CLUTCH PLATEAPPLICATIONS table. Insert top thrust plate with smooth side facingclutch plate. On 1991-to-early 1993 models, install support ring andsnap in place. See Fig. 53. On late 1993 and 1994 models, installsupport ring with step tabs up after installing thrust plate, frictionplates and steel plates. 6) On all model years, Install inner plate carrier intoclutch housing. Install circlip in clutch housing. See Fig. 54.

Fig. 52: Installing Diaphragm Spring & CirclipCourtesy of Volkswagen United States, Inc.

Fig. 53: Installing Support RingCourtesy of Volkswagen United States, Inc.

Fig. 54: Installing Clutch Housing CirclipCourtesy of Volkswagen United States, Inc.

3RD-4TH APPLY CLUTCH

NOTE: Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation.

1) Mark circlip for installation reference and remove.Disassemble clutch plates and round ring. See Fig. 55. Compress springsupport ring, and remove circlip. Remove diaphragm spring circlip anddiaphragm spring. Remove clutch piston. 2) Remove front impeller seal rings. DO NOT remove innerimpeller seal rings unless damaged. Check for worn or damaged partsand replace as necessary.


3) Ensure check ball in clutch housing is not damaged. Pistonseal is part of piston. If damaged, replace 3rd-4th apply clutchpiston. Reassemble 3rd-4th apply clutch. See APPLY CLUTCH PLATEAPPLICATIONS table.

NOTE: Assembled clutch clearance specification is not available from manufacturer. Ensure curved side of diaphragm spring faces piston. Ensure rounded side of round ring and rounded side of thrust plate face each other. Ensure top thrust plate is installed with shouldered side facing circlip.

Fig. 55: Exploded View Of 3rd-4th Apply Clutch (1991-to-Early 1993)Courtesy of Volkswagen United States, Inc.


Fig. 56: Exploded View Of 3rd-4th Apply Clutch (Late 1993-94)Courtesy of Volkswagen United States, Inc.

TRANSAXLE REASSEMBLY

FINAL DRIVE & TRANSFER GEARS

NOTE: Reassembly procedures include bearing and shim adjustments. Perform all steps in the order given. If no parts were replaced, skip adjustment steps and reassemble final drive and transfer gear assembly using new seals. Ensure turning torque of complete assembly is within specifications. See ADJUSTMENT & REASSEMBLY (INPUT TRANSFER GEAR) procedure. If turning torque is not within specifications, check all adjustments.

Fig. 57: Locating Final Drive Roller Bearings, Races & AdjustmentShimsCourtesy of Volkswagen United States, Inc.

Adjustment (Drive Pinion Roller Bearings) 1) Install drive pinion assembly with smaller bearing andinner bearing support (with pinion seal and "O" ring). Install parkinggear (rounded side facing drive pinion gear), park lock lug and largepinion bearing race support.

NOTE: Install drive pinion seal with lip opening facing closest roller bearing.

2) If reusing drive pinion and large pinion bearing, DO NOTremove existing shims from drive pinion shaft. See Fig. 58. Go to step4). If replacing drive pinion and/or pinion bearings, install largepinion roller bearing to drive pinion. 3) Remove large roller bearing race support. Place two .06"(1.5 mm) thick shims onto drive pinion shaft. See Fig. 58. Installlarge roller bearing race support. 4) Install output drive pinion gear and nut. See Figs. 48 and57. Engage parking lug to lock drive pinion shaft. Tighten nut to 184ft. lbs. (250 N.m). 5) If reusing drive pinion and large pinion bearing, go tostep 9). If replacing drive pinion and/or pinion bearings, go to step6). 6) DO NOT rotate drive pinion. Mount a dial indicator ontransaxle case. See Fig. 59. Move drive pinion up and down (DO NOTrotate). Measure and record end play.

Fig. 58: Installing Drive Pinion ShimCourtesy of Volkswagen United States, Inc.

Fig. 59: Checking Drive Pinion Roller Bearing End PlayCourtesy of Volkswagen United States, Inc.

7) Add .008" (.22 mm) to end play measured in step 6). Thisis shim thickness required to preload pinion cover roller bearing. SeeFig. 57. Shims are available in thickness ranging from .040-.106" (1.00-2.70 mm), in .001" (.025 mm) increments. 8) Remove nut, drive pinion gear and bearing. Install shimcalculated in step 7). Apply gear oil to bearings. Install drivepinion gear and nut. Tighten nut to 250 ft. lbs. (339 N.m) to seatbearings. 9) Using INCH-lb. torque wrench, rotate torque wrench atleast 8 turns to determine turning torque. Measure turning torque ofdrive pinion roller bearings. See the DRIVE PINION ROLLER BEARINGSPECIFICATIONS table. Also, see Fig. 60. After turning torque iscorrect, bend locking plate on nut.

DRIVE PINION ROLLER BEARING SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Turning Torque

New Bearings ............... 7-11 INCH Lbs. (.73-1.20 N.m)Used Bearings ............. (1) Same As Before Disassembly

(1) - Recorded during disassembly. See FINAL DRIVE & TRANSFER GEARS under TRANSAXLE DISASSEMBLY.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ


Fig. 60: Checking Pinion Roller Bearing PreloadCourtesy of Audi of America, Inc.

Adjustment & Reassembly (Input Transfer Gear) 1) Ensure inner race for roller bearing is installed intransaxle case. 2) Install input transfer gear with roller bearing and axialneedle bearing (flat side facing input gear) into transaxle case. SeeFigs. 1, 57 and 62. Align lugs on outer roller bearing to fit betweenlugs on inner roller bearing. See Fig. 61. 3) Install outer roller bearing (without dished washer orshim) on input transfer gear. See Figs. 57 and 62. Engage parkinggear. Using an Allen-head socket, tighten fastener nut to 74 ft. lbs.(100 N.m). See Fig. 63. 4) Remove fastener nut. Using a dial indicator, measuredistance between input transfer gear and inner race of roller bearing.See Fig. 64. Measure thickness of dished washer.

Fig. 61: Aligning Lugs On Input Transfer Gear Roller BearingsCourtesy of Volkswagen United States, Inc.

Fig. 62: Locating Input Transfer Gear AssemblyCourtesy of Volkswagen United States, Inc.

Fig. 63: Tightening Fastener Nut On Input TransferGear Roller BearingsCourtesy of Volkswagen United States, Inc.

Fig. 64: Checking Distance Between Input TransferGear & Inner Race Of Roller BearingsCourtesy of Volkswagen United States, Inc.

5) Add dished washer thickness to distance measured in step3). Subtract .007" (.18 mm) to obtain shim thickness for desiredroller bearing preload. Shims are available in thickness ranging from.040-.106" (1.00-2.70 mm), in .001" (.025 mm) increments. 6) Install selected shim. Install dished washer with curvedside facing fastener nut. Apply ATF to bearings. Install and tightenfastener nut to 185 ft. lbs. (250 N.m) to seat bearings. 7) Using INCH-lb. torque wrench, rotate torque wrench atleast 8 turns to determine turning torque. Measure the combinedturning torque of the pinion and input transfer gear roller bearings.Refer to the INPUT TRANSFER GEAR ROLLER BEARING SPECIFICATIONS table.Also, see Fig. 60.

INPUT TRANSFER GEAR ROLLER BEARING SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Turning Torque

New Bearings Without Drive Pinion Bearings ... 18 INCH Lbs. (2.0 N.m) With Drive Pinion Bearings .. (2) 27 INCH Lbs. (3.0 N.m)Used Bearings ............. (1) Same As Before Disassembly

(1) - Recorded during disassembly. See FINAL DRIVE & TRANSFER GEARS under TRANSAXLE DISASSEMBLY.(2) - Based on a drive pinion torque of 9 INCH Lbs. (1.0 N.m).ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

8) Remove fastener nut. If necessary, select a shim and

recheck roller bearing preload. If roller bearing preload is okay,apply Locking Compound (AMV 100 01) to shaft side of roller bearing. 9) Align lugs with notches of opposite roller bearing. SeeFig. 61. Install axial needle bearing with flat side facing driveshaft. Engage parking gear lug. Install fastener nut and tighten to185 ft. lbs. (250 N.m).

Final Drive Assembly 1) Oil bearings and place differential assembly insidetransaxle. Install seals, "O" rings and new bearing races (ifrequired) to bearing carrier and bearing adjuster ring. 2) Install and tighten bearing carrier to 111 ft. lbs. (150N.m). Install locking tab. 3) Install bearing adjuster ring. Tighten adjuster ring. SeeFig. 65. If using original bearings, tighten bearing adjuster ring tomarks made during disassembly. 4) If using new bearings, differential or bearing carrier,tighten the bearing adjuster ring to 37 ft. lbs. (50 N.m). Turn thebearing adjuster ring 5 locking lugs tighter. Install the locking tab.See Fig. 65. 5) Using INCH-lb. torque wrench, rotate torque wrench atleast 8 turns to determine turning torque. Measure combined turningtorque of pinion, input transfer gear and differential side rollerbearings. See the DIFFERENTIAL ROLLER BEARING SPECIFICATIONS table.Also, see Fig. 60.

DIFFERENTIAL ROLLER BEARING SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Turning Torque

Including Transfer & Pinion Bearings New Bearings .................... 33 INCH Lbs. (3.7 N.m) Used Bearings ............... Same As Before Disassembly

Differential Side Bearings Only New Bearings ................. 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.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

6) Install circlips to end of each axle. See Fig. 66. Install"O" rings and new seals to drive axle flange. Fill space between sealand dust lip with multi-purpose grease. 7) Install drive axle flanges to transaxle. Install andtighten differential cover bolts to 21 ft. lbs. (28 N.m). Installspeedometer drive.

Fig. 65: Preloading Differential Side BearingsCourtesy of Volkswagen United States, Inc.

Fig. 66: Installing Circlips To AxlesCourtesy of Volkswagen United States, Inc.

TRANSMISSION

NOTE: Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation. Apply assembly lubrication to all bushings, washers, shims and bearings before installation. See Fig. 28.

1) Input transfer gear, drive pinion and differentialassemblies should be adjusted and installed at this time. Installaxial needle bearing to input transfer gear. See Fig. 67. Install "O"ring and planetary carrier. On 1991-to-early 1993, install small sungear. On all, install axial needle bearing and washers. See Figs. 33and 68. Install the end plate shim for reverse brake clutch plates.See Fig. 69. 2) Install the reverse brake clutch plates. See Fig. 70.Refer to the BRAKE CLUTCH PLATE APPLICATIONS table. Using AssemblyRing (VW 3267), install one-way clutch and secure using a circlip. SeeFigs. 71 and 72.


3) Using a feeler gauge, check installed reverse brake clutchclearance. See Fig. 73. Clearance should be .047-.071" (1.2-1.8 mm).If clearance is not as specified, replace end plate shim. End plateshims are available in thicknesses ranging from .04" (1.0 mm) to .07"(1.9 mm) in .004" (.10 mm) increments.

Fig. 67: Installing Axial Needle Bearing To Input Transfer GearCourtesy of Volkswagen United States, Inc.

Fig. 68: Installing Planetary Carrier & Axial Needle BearingCourtesy of Volkswagen United States, Inc.

Fig. 69: Exploded View Reverse Brake Clutch AssemblyCourtesy of Volkswagen United States, Inc.

Fig. 70: Installing Reverse Brake Clutch PlatesCourtesy of Volkswagen United States, Inc.

Fig. 71: Installing One-Way ClutchCourtesy of Volkswagen United States, Inc.

Fig. 72: Installing CirclipsCourtesy of Volkswagen United States, Inc.

Fig. 73: Checking Reverse Brake Clutch ClearanceCourtesy of Volkswagen United States, Inc.

BRAKE CLUTCH PLATE APPLICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Number Of Plates

Reverse Clutch Inner ................................. 5 Outer ................................. 5


2nd-4th Clutch Inner ................................. 6 Outer ................................. 7ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

4) Install rubber oil splash shield and lower circlip forsupport tube. See Fig. 72. Install washers, bearing and large sungear. Install large sun gear drive shell. See Fig. 74. 5) Install small sun gear drive shell. Install smallplanetary drive shaft. See Figs. 28, 75 and 76. Using a screwdriver,lock small sun gear drive shell to large sun gear drive shell. SeeFig. 77. Install adjustment shim, washer and bolt on end of smallplanetary drive shaft. Tighten bolt to 22 ft. lbs. (30 N.m). 6) Ensure end play is .009-.014" (.23-.37 mm). If end play isnot as specified, recheck assembly or adjustment. See PLANETARYCARRIER under COMPONENT DISASSEMBLY & REASSEMBLY.

Fig. 74: Installing Large Sun Gear Drive ShellCourtesy of Volkswagen United States, Inc.

Fig. 75: Installing Small Sun Gear Drive ShellCourtesy of Volkswagen United States, Inc.

Fig. 76: Installing Small Planetary Drive ShaftCourtesy of Volkswagen United States, Inc.

Fig. 77: Holding Small Sun Gear Drive ShellCourtesy of Volkswagen United States, Inc.

7) Install bearing, washer, and impeller shaft and 3rd-4thapply clutch. See Fig. 78. Install bearing, washer and 1st-3rd applyclutch with turbine shaft assembly. See Fig. 79. Install thrust shimson 1st-3rd apply clutch housing. Install reverse apply clutch andsupport tube. See Fig. 80.

NOTE: Turbine shaft end play was measured before disassembly. If end play is okay, use original thrust shims. If end play is not okay or new parts are installed, calculate difference and install required thrust shims.

8) For checking purposes, install oil pump gasket and oilpump. See Fig. 28. Position dial indicator and Support (VW 387) ontransaxle case. See Fig. 81. 9) Press dial indicator on turbine shaft, and apply .040" (1.0 mm) preload. Move turbine shaft up and down. Turbine shaft end playshould be .019-.047" (.50-1.20 mm). 10) If end play is okay, go to next step. If end play is notokay, install required thrust shims. Thrust shims are available in

thicknesses ranging from .04" (1.0 mm) to .07" (1.8 mm) in .008" (.20mm) increments. Recheck turbine shaft end play. 11) Remove oil pump and oil pump gasket. Install support tubeand .12" (3.0 mm) thick outer splined plate for reverse apply clutch.Ensure groove on support tube engages wedge of one-way clutch. SeeFigs. 28 and 80. 12) Install friction plates and outer splined plates forreverse apply clutch into transaxle case. See Fig. 82. Install 3springs and cap springs. Install the 2nd-4th brake clutch plates.Refer to specifications in the BRAKE CLUTCH PLATE APPLICATIONS table.Also, see Fig. 83. Install 3 spring caps to springs.

Fig. 78: Installing 3rd-4th Apply Clutch & Impeller ShaftCourtesy of Volkswagen United States, Inc.

Fig. 79: Installing 1st-3rd Apply Clutch & Turbine ShaftCourtesy of Volkswagen United States, Inc.

Fig. 80: Installing Support TubeCourtesy of Volkswagen United States, Inc.

Fig. 81: Checking Turbine Shaft End PlayCourtesy of Volkswagen United States, Inc.

Fig. 82: Installing 2nd-4th Brake Clutch Plate & SpringsCourtesy of Volkswagen United States, Inc.

13) DO NOT install top outer splined clutch plate or wavedspring washer. Determine clearance of 2nd-4th brake clutch. Press 2nd-4th brake clutch assembly down. Using a depth gauge, measure distancefrom top of oil pump flange to 2nd-4th brake clutch (inner splined).See Fig. 84. 14) Place a straightedge across top of piston. Place gasketon oil pump flange. Using depth gauge, measure distance fromstraightedge to oil pump flange gasket. See Fig. 85. Subtractthickness of straightedge. 15) Subtract distance measured in step 13) from distance

calculated in step 14). This gives 2nd-4th brake clutch-to-pistondistance. 16) Subtract .14" (3.6 mm) from value calculated in step 15).This determines thickness of last outer splined 2nd-4th brake clutchplate. Outer splined 2nd-4th brake clutch plates are available inthickness ranging from .080-.148" (2.00-3.75 mm), in .010" (.25 mm)increments.

NOTE: Factory uses .14" (3.6 mm) value to allow for waved spring washer being installed with 2nd-4th brake clutch plates.

17) Install 3 spring caps and last outer 2nd-4th brake clutchplate. Install waved spring washer. Install oil pump gasket. Install"O" ring to oil pump, and install oil pump. Install cover for transfergears. 18) Move gear change shaft to "P" position. Push manual valveoperating lever with manual valve into valve body. Tighten set screw.Install sealing plug. See Fig. 25. Install valve body. Install oilfilter screen and oil pan. See Figs. 27, 48, 86 and 87. Install torqueconverter.

Fig. 83: Installing 2nd-4th Clutch PlatesCourtesy of Volkswagen United States, Inc.

Fig. 84: Measuring Oil Pump Flange-To-Clutch PlateCourtesy of Volkswagen United States, Inc.

Fig. 85: Measuring Height Of PistonCourtesy of Volkswagen United States, Inc.

Fig. 86: Installing Manual Valve Operating Lever(097 Shown; 096 Is Similar)Courtesy of Volkswagen United States, Inc.

Fig. 87: Installing Valve BodyCourtesy of Volkswagen United States, Inc.

TRANSMISSION SPECIFICATIONS

TRANSMISSION SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication In. (mm)

Clutch Clearance Apply Clutches ..................................... (1) Brake Clutches 2nd-4th .................... (2) .060-.068 (1.50-1.74) Reverse .......................... .047-.071 (1.2-1.8)

Gear & Shaft End Play Planetary Carrier .................. .009-.014 (.23-.37) 1st-3rd To Reverse Apply Clutch ... .019-.047 (.50-1.20) Turbine Shaft ..................... .019-.047 (.50-1.20)

(1) - Assembled clutch clearance is not available.(2) - See TRANSMISSION under TRANSAXLE REASSEMBLY.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)

Ball Joint Bolt .................................. 26 (35)Differentail Bearing Carrier ................... 110 (150)Differential Housing Cover Bolts ................. 21 (28)Drive Axle Flange Bolts .......................... 33 (45)Drive Pinion Bearing & "O" Ring Support ........ 148 (200)Drive Pinion Nut ............................... 185 (250)Input Transfer Gear Nut ........................ 185 (250)Oil Cooler Banjo Bolts ........................... 26 (35)Small Planetary Drive Shaft Bolt ................. 22 (30)Subframe-To-Transaxle Support Nut ................ 44 (60)Torque Converter Nuts ............................ 44 (60)Transaxle-To-Engine Bolts 10-mm Diameter ................................. 44 (60) 12-mm Diameter ................................. 59 (80)Transaxle-To-Transaxle Support Bolts ............. 44 (60)

INCH Lbs. (N.m)

Detent Spring Screws ............................. 84 (10)Differential Bearing Carrier/Adjuster Locking Tab Bolt ............................... 108 (12)Oil Filter Bolts .................................. 71 (8)Oil Pan Bolts ................................... 108 (12)Oil Pump-To-Transaxle Bolts Step 1 .......................................... 71 (8) Step 2 ........................... Additional 90 DegreesTransfer Gear Cover Bolts ......................... 71 (8)

Valve Body Bolts .................................. 44 (5)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

TECHNICAL SERVICE BULLETINS

POOR SHIFTS & IN LIMP-IN MODE

1991-93 Corrado SLC & Passat (Group 37, TSB No. 37-08, 5-30-93) Some transaxles may have poor shifts or be stuck in limp-inmode. This may be caused by the wire harness shorting out againstclips holding the magnet to valve body. As of transaxle No. 29 03 3,the magnet location has been moved about an inch away. Factoryrecommends using Tester (VAG 1598) to diagnose any electricalproblems. Visually check harness for damage and repair or replace asnecessary. If no other problems are found, replace valve body. Adjustmanual valve. Install oil pan using Oil Pan Gasket (096 321 359A).

REVISED FINAL DRIVE FLUID

1993-94 Corrado SLC, Golf, Golf III, Jetta, Jetta III & Passat (Group 37, TSB No. 93-11, 6-15-93) The final drive fluid used in automatic transaxles has beenchanged. Use SAE 75W/90 Synthetic Final Drive Fluid (G 052 145 A2)only. Drain fluid. Fill final drive with 1.1 qts. (1.0L) of syntheticfluid. DO NOT mix fluids.

REVISED FILLER & DIPSTICK

1993-94 Golf III & Jetta III (Group 38, TSB No. 93-03, 9-16-93) As of transaxle No. 24 05 3, a revised dipstick (Red handle)and filler tube is now installed. Ensure dipstick and filler tubematch. The early version uses Filler Tube (096 321 405B) and a Yellow-handled Dipstick (096 321 431). The revised version uses FillerTube (096 321 405E) and a Red-handled Dipstick (096 321 431C).

NO "D" RANGE, OTHER RANGES OKAY

1993-94 Corrado SLC & Passat (Group 38, TSB No. 93-02, 5-30-93) Some vehicles may not move in "D" range, but work okay in allother ranges. This may be caused by the manual valve.

NOTE: VAG Scan Tool (1551) will indicate diagnostic trouble code 00652 (gear monitoring).

To correct this, remove oil pan. Place gear selector in Parkposition. Loosen adjustment bolt. Push operating rod with manual valveinto valve body as far as possible. See Figs. 48 and 86. Tightenadjustment bolt. Install oil pan and fill with fluid. Using scan tool,clear stored diagnostic codes. Return engine and transaxle to base

settings. Road test vehicle. Check for any diagnostic trouble codes.

WIRING DIAGRAMS

Fig. 88: 1991-94 Schematic (Corrado & Passat)


Fig. 89: Schematic (1993-94 Golf & Jetta; 1994 Golf III & Jetta III)

END OF ARTICLE

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At 096 Overhaul