Planetary Gearbox, Disassembling and Assembling
Planetary gearbox, disassembling and assembling
I - ATF pump to support tube, removing and installing
II - Reverse clutch -K2- to large sun gear, removing and installing
III - Free wheel and reverse gear brake -B1- removing and installing
IV - Planet carrier, removing and installing
Note:
- It is not necessary to remove input gear (arrow)
- Removing and installing input gear.
I - ATF pump to supporting tube, removing and installing
1. Bolt
- Qty. 7
- Tighten to 8 Nm and turn 90° further
- The turning further of 90° may be done in several stages
2. ATF pump with -B2- piston
- Spare part is allocated according to transmission code letters
- Disassembling and assembling
3. O-ring
- Always replace
- Place on ATF pump
4. Gasket
- Always replace
5. Spring cap, City. 6
- Install 3 spring caps after installing first outer plate
- Install 3 spring caps before installing last outer plate
6. Spring
- Qty. 3
7. Retaining ring
8. Shim
9. Outer plate -B2
- 3mm thick
10. Inner plate -B2
- Before installing place new inner plates in ATF for 15 minutes
11. Outer plate -B2
- Always install 2 mm thick outer plates
12. Outer plate -B2
- Fit 3 mm thick outer plate to supporting tube
13. Supporting tube -B2
- For the B2- plate package
- Spare part is allocated according to transmission code letters
- Insert so that groove engages in wedge of free wheel
14. Transmission housing with clutches installed
15. Strainer
- Not installed until transmission manufacture date 14.02.0.
II - Reverse gear clutch -K2- to large sun gear, removing and installing
1. Reverse gear clutch -K2-
- Disassembling and assembling
2. Shim
- Determining thickness = Adjusting clutch play between -K1- and -K2-.
- 1 or 2 shims can be installed
3. 1st to 3rd gear clutch -K1
- Spare part is allocated according to transmission code letters
- The clutches -K1- and -K3- are pressed together
- Disassembling and assembling
4. Seal
- Always replace
- To replace press -K1- off -K3-
5. 3rd and 4th gear clutch -K3 with turbine shaft
- Spare part is allocated according to transmission code letters
- Disassembling and assembling
- The clutches K1- and K3- are pressed together
- There are two different types
6. 1st to 3rd gear clutch -K1- with 3rd and 4th gear clutch - K3
- The clutches K1- and K3- are pressed together
- Pressing -K1- off K3-
- Pressing -K1- onto -K3-
7. Axial needle bearing with washer
- Axial needle bearing faces small input shaft
8. Small input shaft
9. Needle bearing
10. Axial needle bearing
11. Large input shaft
12. Axial needle bearing
13. Axial needle bearing washer
- With shoulder
14. Large sun wheel
15. Axial needle bearing
16. Axial needle bearing washer
17. Transmission housing with freewheel and circlips installed
III - Freewheel and reverse gear brake -B1-, removing and installing
1. Circlip
- For supporting tube -B2-
- Installation position: Circlip open ends faces free wheel retaining wedge
2. Circlip
- For freewheel
- Installation position: Circlip open ends faces free wheel retaining wedge
3. Freewheel with -B1- piston
- Before removing freewheel, remove valve body and sealing plugs
- Disassembling and assembling
4. Dished spring
- Install with convex facing freewheel
5. Pressure plate -B1-
- Install with flat side facing plates
- Spare part is allocated according to transmission code letters
6. Inner plate, -B1-
- Quantity of inner plates -B1-
- Before installing place plates in ATF for 15 minutes
7. Outer plate, -B1-
- Quantity of outer plates -B1-
8. Shim
- Determining thickness
9. Transmission - housing with planet carrier installed
IV - Planet carrier and transmission housing with input gear and cover
1. Planet carrier
- Adjusting
2. O-ring
- Always replace
- Insert in planet carrier
3. Axial needle bearing washer
4. Axial needle bearing
5. Axial needle bearing washer
- Install smooth side in input gear
6. Transmission - housing with input gear installed
7. Input gear
- Do not remove to disassemble planetary gearbox
- Removing and installing input gear or axial needle bearing for planet carrier
8. Planet carrier shim
- Determining thickness.
- Adjusting planet carrier
9. Washer
10. Bolt, 30 Nm
- For small input shaft
11. Spacer bush
- Clip qty. 7 into gasket
12. Gasket
- Always replace
13. Cover
14. Bolt, 8 Nm
Planetary gearbox, disassembling and assembling
Special tools and equipment
- VW 309 Holding plate
- VW 313 Support clamp
- VW 353 Transmission support
- VW 402 Thrust plate
- VW 412 Press tool
- VW 415A Tube
- VW418A Tube
- 3110 Tube
- 3267 Assembly ring
- 3336 Transmission lifting beam
- V.A.G 1331 Torque wrench
Disassembling planetary gearbox
- Transmission attached to transmission support device 3336
- Place container under transmission.
- Remove sealing plug -1- and ATF overflow pipe -2-.
- Drain ATF.
3. Sealing plug
4. Cap
- Seal ATF cooler connections.
- Take out torque converter.
- Secure transmission to assembly support with bolts -1- and -2- (M10).
- Remove transmission support device 3336.
- Remove transmission housing cover with gasket (arrow).
- Remove oil pan.
- Remove ATF screen.
- Remove valve body with conductor strip.
- Pull out sealing plugs for -B1- (arrow).
- Remove ATF pump bolts (arrows).
- Screw bolts -A- (M8) into tapped holes of ATF pump.
- Press ATF pump off gearbox by turning bolts -A- evenly.
- Remove strainer if installed.
Strainer is installed in ATF pipe.
- Remove all clutches with supporting tube, -B2- plates, springs and spring caps together.
Clutches -K1- and -K3- are pressed together.
Clutch -K1- must only be pressed off -K3- if one of clutches is to be disassembled or replaced.
Pressing -K1- off -K3-.
- Insert screwdriver through hole of large sun gear to loosen and tighten bolt for small input shaft.
- Loosen small input shaft bolt -arrow-.
- Remove small input shaft bolt, washer and shim.
Planet carrier axial needle bearing remains in gearbox/input gear.
- Pull out small input shaft.
- Pull out large input shaft (arrow).
- Pull out large sun gear (arrow).
- Remove transmission vehicle speed sender -G33-.
- Remove supporting tube circlip -a- and freewheel circlip -b-.
- Take freewheel out of transmission housing by pulling on freewheel 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 the input gear to disassemble the planetary gearbox. Removing and installing input gear.
- Assembling planetary gearbox.
Pressing clutch -K1- off -K3-
The clutches -K1- and -K3- are pressed together.
Clutch -K1- must only be pressed off -K3- if one of the clutches is to be disassembled or replaced.
- Ensure tool press surface is flat and not damaged.
Pin of tube 3110 faces to plate VW 402.
- Hold turbine shaft when pressing off.
Pressing clutch -K1- onto -K3-
- Insert new O-ring in recess in turbine shaft (arrow).
- Moisten O-ring with ATF.
- Clip (2) axial needle bearing (1) with washer to 3rd and 4th gear clutch -K3-.
- Ensure tool press surface is flat and not damaged.
- Prepare -K1- and -K3- for pressing as illustrated.
- Before pressing on, align VW 418 A centrally onto surface for axial needle bearing (this illustration shows -K3- from below).
- Press clutch -K1- on carefully until stop is perceptible.
Note: Do not exert further pressure onto clutches!
Assembling planetary gearbox
- Fit O-ring into planet carrier.
Note: After replacing planet carrier, adjust.
- Insert axial needle bearing with washers and planet carrier in input gear.
1. Input gear is installed in transmission housing.
2. Axial needle bearing washer, insert smooth side into input gear.
3. Axial needle bearing
4. Axial needle bearing washer
5. Install planet carrier with seal fitted
- Place washer and axial needle bearing on small sun gear in planet carrier.
- Centralize washer and axial needle bearing in small sun gear.
- Insert inner and outer -B1- plates.
- Insert pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates. Replacement part is allocated according to transmission code letters.
- Insert dished washer with convex facing toward freewheel.
Note: When replacing
- Transmission housing
- Freewheel
- Piston for reverse gear brake -B1-
- or plates
Then adjust -B1-.
- Preload freewheel rollers with assembly ring 3267 and insert freewheel.
- Install circlip for freewheel -b- and circlip for supporting tube -a-.
- Insert circlip gaps over freewheel retaining wedge (arrow).
- Install transmission vehicle speed sensor -G38-.
- Perform measurement check of -B1-.
- Insert components into transmission housing starting with the large sun wheel down to small input shaft.
1. Large sun wheel
2. Needle bearing washer (collar faces to large sun wheel)
3. Axial needle bearing
4. Large input shaft
5. Axial needle bearing
6. Needle bearing
7. Small input shaft
- Installing small drive shaft bolt -1- with washer -2- and shim -3-.
Tightening torque 30 Nm.
- Insert shim -3- onto small input shaft shoulder (arrow).
Determining shim thickness = adjusting planet carrier.
- Perform planet carrier check measurement.
- Clip axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.
1. Axial needle bearing with thrust washer
2. 3rd and 4th gear clutch -K3
- Ensure piston rings seat correctly on -K3-.
- Ensure that ends of piston rings are hooked together.
- Insert 1st to 3rd gear clutches -K1- with 3rd and 4th gear clutch -K3-.
- Insert shims -arrow- in -K1-.
Note:
- Remeasure shim when replacing-K1, -K2- or ATF pump adjusting clutch play between -K1- and -K2-.
- 1 or 2 shims can be installed.
- Insert reverse gear clutch -K2-.
- Insert supporting tube for -B2- plate set (arrow) so that supporting tube groove engages in freewheel wedge.
- Install -B2- plates as follows:
- First insert a 3 mm thick outer plate.
- Insert three spring caps in outer plate.
- Insert compression springs (arrows).
- Insert all, but last outer plate
- Insert three spring caps onto compression springs.
- Insert last outer plate -3 mm thick-.
Determine shim.
- Install shim -a-.
- Insert retaining ring -b- onto shim. Smooth side facing shim.
Note: When replacing
- Transmission housing
- Supporting tube
- ATF pump
- Retaining ring
- or the plates
then the 2nd and 4th gear brakes -B2- are to be adjusted.
These components are allocated as replacement parts according to transmission code letters.
- Clean strainer.
- Install strainer.
Strainer is located in ATF cooler pipe.
- Install ATF pump seal.
- Install O-ring on ATF pump.
- Install ATF pump.
- Tighten bolts evenly, crosswise.
Tightening torque: 8 Nm.
Note: Ensure that the O-ring is not damaged.
- Turn bolts 90° further.
Turning further can be done in several stages.
- Check measurement of clutch play.
- Insert sealing plugs with O-rings -arrow-.
Installation position: Tab engages in oil channel.
- Install valve body with conductor strip.
- Install oil pan.
- Install cover (arrow) with gasket and spacer bushings.
Tightening torque: 8 Nm.
- Screw in ATF overflow pipe -1- and sealing plug -2- with new seal hand tight.
- Install torque converter.
- Install transmission.
- Fill with 3 liters of ATF, and check ATF level and top-up.