Part 1
Planetary gear, disassembling and assembling - 5 Spd. A/T 01V Front and All Wheel Drive
Note:
^ General repair notes
^ Rules of cleanliness for working on automatic transmissions.
^ Lubricate O-rings and gaskets with ATF or Vaseline before installing to prevent rings from being pinched when inserting.
^ Attach mount and adjustment shims only with Vaseline.
^ Use only ATF or Vaseline in areas near ATF. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.
Disassembling
^ attach Transmission to assembly stand
- Remove torque converter.
- 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.
Automatic transmission 01V Front Wheel Drive:
- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
- Loosen front final drive cover bolts in sequence - 14 to 1 - and then remove completely.
- Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.
CAUTION:
^ Slowly and carefully remove cover for front final drive from transmission housing. The spur gears can otherwise fall out of the transmission.
^ Do not reinstall spur gears that have fallen to the ground. The transmission must be replaced in this case.
- Lift off cover for front final drive.
- Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
CAUTION:
^ Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.
^ For this reason, mark installation position of intermediate pinion and pinion gear.
- Remove pinion gear together with intermediate pinion, while doing so pull drive pinion - 2 - slightly toward rear.
- Remove drive pinion - 2 -
- Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
- Remove coil spring - 3 - from pinion shaft.
Automatic transmission 01V All Wheel Drive:
- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
- Remove locking bolt - A - and allow axle oil to drain from transfer case.
- Loosen transfer case housing bolts - arrows - in a diagonal sequence and then remove them completely.
CAUTION:
Carefully and slowly pull transfer case housing off of transmission toward rear. The Torsen differential could otherwise fall out of the transmission.
- Remove Torsen differential - arrow - from input shaft.
- Place old oil collecting and extracting device V.A.G 1782 beneath transmission.
- Remove bolts - arrows - at intermediate flange for front final drive.
- Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782
CAUTION:
^ Slowly and carefully remove intermediate flange for front final drive from transmission housing. The spur gears can otherwise fall out of the transmission.
^ Do not reinstall spur gears that have fallen to the ground. The transmission must be replaced in this case.
- Lift off intermediate flange for front final drive.
- Cover entire splines - arrow - on input shaft with insulating tape without wrinkling or overlapping to avoid damaging shaft seal in front final drive intermediate flange when removing drive pinion - 2 -.
CAUTION:
^ Intermediate pinion - 1 - and pinion gear - 3 - must be reinserted in the same position to maintain running direction.
- Mark installation position of intermediate pinion - 1 - and pinion gear - 3 -.
- Remove pinion gear together with intermediate pinion, while doing so pull drive pinion 2 - slightly toward rear.
- Remove drive pinion - 2 -.
- Remove adjustment shim - 1 - and axial needle bearing - 2 - from input shaft.
- Remove coil spring - 3 - from pinion shaft.
Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
- 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 bolts - arrows - and remove baffle.
- 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 removing flange shaft.
- 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.
Note:
^ Milky green cover in ATF oil pan means there is damage to the torque converter clutch.
- 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 (on bottom side of valve body - arrow -) - 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 - 9 to 1 - in 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 -.
- Remove adjustment shim - 1 - and axial needle bearing - 2 -.
- Lift tower "II" - 1 - out of transmission housing.
- Twist tower "II" - 1 - and place together with input shaft in mounting device T10283.
- Remove sun shaft - 1 - with intermediate shaft - 2 - with inner plate carrier.
- Disassemble the following components:
1. Sun shaft
2. Thrust washer
3. Axial needle bearing
4. Angle washer
5. Intermediate shaft with inner plate carrier
6. Thrust washer
7. Axial needle bearing
8. Thrust washer
- Remove axial needle bearing - 1 -.
- Remove sun gear "I" - 1 -.
- Remove planetary gear set "I" and "II" - 1 -.
- Remove angle washer - 3 -, axial needle bearing - 2 - and thrust washer - 1 -.
- Remove shaft with ring gear "I" - 4 - thrust washer - 3 -, axial needle bearing - 2 - and angle washer - 1 -.
- Remove ribbed cup - 1 -.
- Remove circlip - arrow - for tower "I".
- Turn back knurled nut of lifting device T10287.
- Insert lifting device into tower "I" until stop.
- Tighten knurled nut of lifting device in clockwise direction.
- Check lifting device in tower "I" for proper seating.
- Lift tower "I" out of transmission housing by hand.
- Place tower "I" in mounting device T10282.
- Remove sun gear "III" - 1 - with lower angle washer - 2 -, axial needle bearing - 3 - and upper angle washer - 4 - from transmission housing.
Note:
^ Upper angle washer - 4 - possibly adheres to underside of tower "I".
Assembling
- Check lifting device in tower "I" for proper seating.
- Lift tower "I" out of mounting device T10282 by hand and lay aside on workbench.
- Attach the following components to input shaft of tower "I" - 5 -:
4 - Upper angle washer - angled edge points up toward tower "I"
3 - Axial needle bearing
2 - Lower angle washer - angled edge points toward axial needle bearing
1 - Sun gear "III" - outer splines of sun gear must engage in splines of clutch "F"
Automatic transmission 01V Front Wheel Drive:
- Secure sun gear "III" on input shaft without play, using assembly sleeve T10290, as depicted in illustration, thread stud bolt - 1 - into bore identified by "A" - arrow A - and hand-tighten.
CAUTION:
^ Stud bolt must not be threaded in bore identified by "B" under any circumstances, or splines will be damaged.
^ Bore "A" faces toward sun gear "III".
Automatic transmission 01V All Wheel Drive:
- Secure sun gear "III" on input shaft without play, using assembly sleeve T10290, as depicted in illustration, thread stud bolt - 1 - into bore identified by "B" - arrow B - and hand-tighten.
CAUTION:
^ Stud bolt must not be threaded in bore identified by "A" under any circumstances, or contact surface will be damaged.
^ Bore "A" faces toward sun gear "III".
Automatic Transmission 01V, Front Wheel Drive and All Wheel Drive:
- Check whether fitting keys - arrow - are inserted centrally on both sides of cylinder "D/G".
- Bring tower "I" into installation position.
^ Oil bores - arrows - on cylinder "D/G" face toward underside of transmission and must align with openings in transmission housing.
- Insert tower "I" completely into transmission housing.
^ Tower "I" must be inserted far enough that circlip groove is free.
- Loosen knurled nut and remove lifting device T10287.
- Carefully insert circlip - arrow - for tower "I" into transmission housing.
CAUTION:
Make sure that circlip is seated evenly all around in groove of transmission housing, if necessary, drive circlip into groove all around using drift.
- Loosen stud bolt and remove assembly sleeve T10290.
Note:
^ Depicted in the illustration with Automatic Transmission 01V All Wheel Drive.
- Insert ribbed cup - 1 -.
- Attach angle washer - 1 - on tower "I".