Planetary Gearbox Disassembly/Assembly
PLANETARY GEARBOX, DISASSEMBLING/ASSEMBLING 096 TRANSMISSION
Planetary gearbox, disassembling
- Seal ATF cooler connections.
- Drain ATF.
ATF can be removed using VAG 1358A extraction system with VAG 1358A/l probe, or EZ1 fluid evacuator.
- Remove torque converter.
- Secure transmission to assembly support with bolts -1- and -2-.
- Remove transmission housing cover with gasket (-arrow-).
- Remove sump.
- Remove ATF screen.
- Remove valve body.
- Remove sealing plugs for -B1-
To remove ATF pump:
- Remove ATF pump bolts.
- Screw bolts -A- (M8) into tapped holes of ATF pump
- Press ATF pump off transmission by turning bolt. -A- evenly.
- Take out all clutches with supporting tube, -B2- plates springs and spring caps together
- Insert screwdriver through hole of large drive shaft and large sun gear to loosen and tighten bolt for small drive shaft.
- Loosen small drive shaft bolt -arrow-.
- Remove small drive shaft bolt, washer and shim.
Planet carrier axial needle bearing remains in transmission/input gear.
- Pull out small drive shaft.
- Pull out large drive shaft (-arrow-).
- Pull out large sun gear (-arrow-).
- Remove supporting tube circlip -a- and tree wheel circlip -b-
- Remove free wheel from out of transmission housing by pulling on free wheel retaining wedge arrow with pliers.
- Pull out planet carrier with dished spring
- Remove reverse gear brake -B1- plates.
Note:
It is not necessary to remove input gear to (disassembleing) the planetary gearbox.
- Assembling planetary gearbox
Planetary Gearbox1 Assembling
- Install axial needle bearing with washer onto input gear.
1 - Axial needle bearing washer
2 - Axial needle bearing
3 - Axial needle bearing washer (install smooth side into input gear)
4 - Input gear (installed in transmission housing)
- Install O-ring in planet carrier
Note:
After replacing planet carrier, adjust.
- Install washer and axial needle bearing into planet carrier.
1 - Axial needle bearing
- Transmissions up to 12.92: outer diameter 41.0 mm (1.61 in.)
- Transmissions from 01.93: outer diameter 39.1 mm (1.54 in.)
2 - Axial needle bearing washer
3 - Small sun gear
- Cannot be removed for transmissions from 01.93 ~ page 00-5
4 - Planet carrier
- Install planet carrier into input gear.
- Centralize washer and axial needle bearing in small sun gear.
- Install inner and outer -B1- plates.
- Install pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates
- Install dished washer with convex side facing toward free wheel.
Note:
When replacing:
- Transmission housing
- Free wheel
- Piston for reverse gear brake -B1-
- or plates
then adjust -B 1-
- Preload free wheel rollers with 3267 assembly ring and install free wheel.
- Install circlip b- for free wheel and circlip a for supporting tube
- Install circlip gaps over free wheel retaining wedge (-arrow-)
- Carry Out check measurement of -B1-
- Install washer with axial needle bearing in large sun gear.
1 - Axial needle bearing
2 - Washer with shoulder (install with smooth side facing axial needle bearing)
3 - Large sun gear
- Install large sun gear with bearing.
- Centralize both washers with axial needle bearing between sun gears.
- Install axial needle bearing and needle bearing in large drive shaft.
- Install large drive shaft with bearing.
- Install small drive shaft.
- Install small drive shaft bolt -1- with washer -2- and shim -3-.
- Tightening torque: 30 Nm (22 ft lb)
Note:
Install shim -3- onto small drive shaft shoulder (-arrow-).
Determining shim thickness Planet carrier, adjusting.
- Carry out planet carrier check measurement.
- Install axial needle bearing with washers in -K3-
1 - Axial needle bearing washer
2 - Axial needle bearing
3 - Axial needle bearing washer (install with smooth side facing -K3-)
4 - 3rd and 4th gear clutch -K3-
Transmissions from 01-93: -K3- clutch operates Only 4th gear.
Note:
Make sure that piston rings seat correctly
- Install axial needle bearing with washer on 4th gear clutch -K3-
1 - Axial needle bearing with washer
- Moisten axial needle bearing washer with ATF so that bearing -1-, when installing sticks to -K3-
- Install bearing washer on K3-.
2 - 3rd and 4th gear clutch -K3-
- Install 3rd and 4th gear clutch -K3.
- Transmissions from 01-93; -K3- clutch operates only 4th gear
- Install shims -a- in -K1-.
Notes:
- Re-measure shim when replacing -K 7-, -K2- or ATF pump.
- 1 or 2 shims can be installed.
- Install 1st to 3rd gear clutch -K1-.
- Install reverse gear clutch -K2-.
- Install supporting tube for plate set -B2- (-arrow-) so that supporting tube groove engages in free wheel wedge.
- Install -B2- plates as follows:
- First install a 3 mm (O.118 in.) thick outer plate.
- Install three spring caps in Outer plate.
- Install compression springs (-arrows-).
- Install all but the last outer plate.
- Before installing the last outer plate instal three spring caps onto compression springs.
Note:
When replacing:
- Supporting tube
- the ATF pump
- or the plates
then the 2nd and 4th gear brakes -B2- are to be adjusted.
- Replace corrugated washer.
- Replace ATF pump seal.
- Install O-ring on ATF pump.
- Install ATF pump.
- Tighten bolts evenly, alternating cross-wise.
- Tightening torque: 8 Nm (71 in lb) plus in additional 1/4-turn (90°)
- Additional 1/4-turn can be done in several stages.
Note:
Make sure that the O-ring is not damaged.
- Carry Out check measurement of clutch play.
- Install sealing plugs, valve body and oil pan.
- Install cover with gasket and spacer bushes.