ATF Pump (With Assembled Transmission), Completely Removing and Installing

ATF pump (with assembled transmission), completely removing and installing - 5 Spd. A/T 01V Front and All Wheel Drive

Removing

^ Attach transmission to assembly stand

- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

CAUTION:
Wear eye protection.

- Remove ATF drain plug - 1 - and allow ATF to drain.

Note:
^ Observe disposal regulations.
^ Rest of ATF remains in the ATF oil pan.

- Remove torque converter.

- Remove right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.
- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
- Pull out right flange shaft.

- Loosen final drive cover bolts in sequence - 12 to 1 - and then remove completely.

CAUTION:
^ Slowly and carefully remove final drive cover from transmission housing. Otherwise differential can fall out of transmission.
^ A differential that has fallen onto the floor must not be installed again. The transmission must be replaced in this case.

- Remove final drive cover.

CAUTION:
^ Ensure tapered roller bearing outer race and differential adjusting screw do not fall out of final drive cover.
^ Tapered roller bearing outer race must be installed in the same location.
^ The shim must be the correct size and must not be replaced by a shim with a different thickness.

- Carefully remove differential - arrow -.

- Remove left drive flange mounting bracket - arrows -.
- Pull out left drive flange.

Note:
^ When sliding off, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

- Loosen ATF oil pan bolts - arrow - in a diagonal sequence and then remove them completely.
- Remove ATF oil pan.

- Remove ATF screen bolts - arrows -.
- Pull ATF filter off of valve body.

- Remove circlip - arrow - for wiring harness/harness connector.
- Remove wiring harness/harness connector by pressing inward.

- Remove bolt - arrow - and remove Transmission Vehicle Speed Sensor (VSS) G38 / Transmission Output Speed (RPM) Sensor G195.

- In a transmission with hydraulic control "E18/2", disengage electrical connector to Transmission Input Speed (RPM) Sensor G182 at valve body - arrow - and disconnect connector.

- Loosen valve body bolts - 17 to 1 - in sequence and remove them completely.

CAUTION:
^ Only the designated bolts must be removed; bolt - 6 - is only on transmissions with hydraulic control "E17".
^ When removing other bolts, the function of the valve body can be influenced or the valve body splits up.
^ Note the different lengths of the bolts.

- Carefully remove valve body from transmission.

CAUTION:
Only transmissions with hydraulic control "E17": Do not rest valve body on Transmission Input Speed (RPM) Sensor G182 arrow - (on bottom side of valve body) - risk of damage.

- Pull sealing sleeves - arrows - in inlet bores toward clutches "C", "A", "B", "E" and toward torque converter clutch using extracting handle T10271.

- Remove 3 securing rings - 1 -.
- Remove coil springs - 2 -.
- Pull out sealing sleeves - 3 -, using extracting handle T10271.
- Rotate transmission on assembly stand.

^ ATF pump faces upward.

- Loosen ATF pump bolts in - 9 to 1 - sequence and remove them completely.
- Remove bolts with sealing washers.

- Secure puller for ATF supply T10286 to stator shaft and pull ATF supply firmly upward.

If ATF pump cannot be loosened:

- On the bottom side of the transmission, place a screwdriver between sun gear "I" and ribbed cup and pry component above sun gear upward - arrow -.

Installing

- Check if tower "II" is still inserted correctly.
- Measure distance between contact surface for adjustment shim on tower "II" and contact surface for ATF pump on transmission housing.

^ Dimension - a - = at least 6.0 mm.
^ Adjustment shim may not be installed.

If dimension - a - is exceeded, the tower "II" would be pulled out of disc contact during removal.

- Remove tower "II" and then reinstall.

- Place previous adjustment shim - 1 - on plate carrier "C".

- Replace 2 rectangular rings on input shaft.
- Before inserting, thinly coat rectangular rings on input shaft with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in the input shaft groove.

- Thinly coat back side of axial needle bearing - 2 - with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Append axial needle bearing to ATF pump - 1 -.

^ Closed side of axial needle bearing faces toward ATF pump.

- Replace rectangular rings - 3 - and - 4 - on stator shaft.
- Before inserting, lightly coat rectangular ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.
- Make sure that rectangular rings are fully seated all around in the stator shaft groove.

- Engage ends of installed rectangular rings - arrows -, as depicted in illustration.

- Replace O-ring - 1 - on ATF supply.
- Thinly coat O-ring with Vaseline. Use only Vaseline, other lubricating substances cause functional problems in the hydraulic transmission control.

- Align coated plates - 3 - of clutch "C" using centering tool T10288/1, to do so let pins - 2 - and - 4 - engage in splines of all coated plate.
- Align lining discs to ATF pump housing by inserting centering pins - 1 - and - 5 - into appropriate holes on ATF pump.

^ Centering pins fit only in one position.

- Hold centering tool in this position and insert wedge T10288/2 from side between waved washer and piston "F" - arrow -.

^ Wedge must secure all plates in current position.

- Remove centering tool T10288/1, wedge T10288/2 remains inserted.

- Align plate carrier for clutch "C" using centering tool T10288/3, install guide pins T10288/4 into transmission housing.

^ Bores of centering tool and transmission housing only fit in one position.

- Carefully remove centering tool T10288/3 upward, guide pins T10288/4 remain in transmission housing.

^ Plate carrier for clutch "C" may no longer be turned.

- Attach puller for ATF supply T10286 at stator shaft.
- Bring ATF supply to installation position.

^ Recess for flange shaft faces toward valve body side.

- Attach ATF supply with corresponding bores onto guide pins T10288/4.
- Carefully insert ATF supply into transmission housing and push forcefully.
- Bring ATF supply to final installation position by alternately tightening two opposing attachment bolts each.

- Remove wedge 10288/2 using hook 3438.
- Remove Puller for ATF supply T10286.
- Remove guide pins T10288/4.

- Insert ATF pump bolts with new sealing washers into ATF pump housing.
- Tighten ATF pump bolts - 1 to 9 - in sequence.

^ Tightening torque: 10 Nm.

Note:
^ Check for correct ATF pump installation: You must be able to rotate the input shaft. Otherwise, the last clutch plate "C" may have been pinched during installation and bent. In this case, remove ATF pump again and check discs for damage.

- Attach Dial gauge VAS 6080 with Dial gauge holder VW 387 to transmission flange.
- Insert Dial gauge VAS 6080 with dial gauge extension onto input shaft of transmission, as depicted in illustration.
- Set dial gauge to "0".
- To protect against damage, cover input shaft with insulating tape.
- Move input shaft up and down using pliers, while doing so avoid lateral movement.
- Read input shaft axial clearance on dial gauge.

^ Specified value: 0.10 to 0.30 mm.

If specified value is not obtained:

- Remove ATF pump again.

- Determine correct adjustment shim - 2 - on tower "II" item - 1 - according to the following table.

^ Measured axial clearance too small: Install respectively thinner shim.
^ Measured axial clearance too large: Install respectively thicker shim.

- Reinstall ATF pump with new adjustment shim, new sealing washers and new O-ring
- Check axial clearance of input shaft again

If specified value is again not obtained:

- Repeat adjustment.

If specified value is obtained:

- Rotate transmission on assembly stand.

^ Valve body side points upward.

- Press sealing sleeves - 3 - into transmission housing holes to stop.
- Insert coil springs - 2 - and secure with circlips - 1 - by pressing circlips into hole down to shoulder.

CAUTION:
Only transmissions with hydraulic control "E17": Do not rest valve body on Transmission Input Speed (RPM) Sensor G182 arrow - (on bottom side of valve body) - risk of damage.

- Position valve body on transmission housing without force while inserting notched disc pins - 1 - into selector slide groove - 2 -.
- Position valve body bolts.

Note:
^ Note different length of bolts.

^ Bolt - 6 - is only present on transmissions with hydraulic control "E17".
^ On a transmission with hydraulic control "E1812", ensure electrical wire to Transmission Input Speed (RPM) Sensor G182 is not pinched between transmission housing and valve body.

- Tighten valve body bolts in 2 stages as follows:

- Replace O-rings for wiring harness/harness connector.
- Connect wiring harness connector - arrow - to transmission housing.

^ Installation position: Retainers - 1 - and - 2 - at collar are horizontal, leveled side - arrow - of connector must be parallel to ATF oil pan sealing surface.

- Position wiring harness connector securing clip - arrow - and ensure it locks securely.

- Tighten bolt - arrow - for Transmission Vehicle Speed Sensor (VSS) G38 / Transmission Output Speed (RPM) Sensor G195.

^ Tightening torque: 10 Nm.

- With a transmission with hydraulic control "E18/2", connect electrical connector to Transmission Input Speed (RPM) Sensor G182.
- Clip electrical harness connector into valve body mount - arrow -.
- Replace ATF filter.

- Position ATF filter on valve body and tighten - arrows -.

^ Tightening torque: 5 Nm.

Note:
^ Clean magnets (6x) in ATF oil pan.
^ Ensure full surface contact of the magnets in the ATF oil pan.

- Install ATF oil pan - arrow - with new seal.
- Tighten bolts for ATF oil pan in diagonal sequence in stages.

^ Tightening torque: 10 Nm.

- If necessary, replace flange seal for left flange shaft.
- Replace O-ring - arrow B - in mounting bracket for left flange shaft.

Note:
^ Disregard - arrow A -.

- Replace final drive/transmission housing double shaft seal if necessary.

- Completely cover splines - arrow - on left flange shaft with insulating tape without wrinkling or overlapping to avoid damaging final drive/transmission housing double shaft seal when installing flange shaft.
- Insert left flange shaft into transmission.

Note:
^ When sliding on, left drive flange must be carefully guided by hand to prevent damage to the double seal in final drive/transmission housing.

- Tighten left flange shaft mounting bracket bolts - arrows -

^ Tightening torque: 23 Nm.

CAUTION:
^ Ensure tapered roller bearing outer race and differential adjusting screw do not fall out of final drive cover.
^ Tapered roller bearing outer race must be installed in the same location.
^ The shim must be the correct size and must not be replaced by a shim with a different thickness.

- Replace O-ring - arrow - in final drive cover.
- If necessary, replace flange seal for right flange shaft.

- Carefully install differential - arrow -.

- Position final drive cover on transmission housing.
- Tighten final drive cover bolts in 2 stages as follows:

- Tighten right flange shaft bolt - arrow - by installing 2 bolts in flange and counterholding flange shaft using a pry bar.

^ Tightening torque: 23 Nm.

- Remove transmission from assembly stand.

- Insert torque converter and secure against falling down with Bracket 30-211 A.
- Check installation dimension of torque converter.
- Fill ATF and check ATF level.
- Fill axle oil in front final drive and check oil level.
- Top off axle oil in transfer case and check oil level.

Torque specifications