Gearbox 001 PDF

Service 5
Workshop Manual
FABIA 2000 ³
Automatic Gearbox 001
Edition 07.00
Gearbox code ESK GJF GJG
Service Department. Technical Information Printed in Czech Republic

S00.5318.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5318.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ Automatic Gearbox 001
List of Supplements to Workshop Manual

FABIA 2000 ³
Automatic Gearbox 001
Edition 07.00
Suppleme
Edition Subject Article Number
nt
07.00 Basic Edition S00.5318.00.20
1 12.02 Supplement to Basic Edition S00.5318.01.20
2 04.05 Supplement to Rep. - Gr. 00, 01, 37, 38, 39 S00.5318.02.20
Edition 04.05 List of Supplements

S00.5318.02.20
List of Supplements Edition 04.05

S00.5318.02.20
Table of Contents
00 – Technical Data
Technical Data for the Gearbox ..................................................................... 00-1 page 1
- Identification of the gearbox ......................................................................... 00-1 page 1
- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1 page 2
- Capacity ................................................................................................. 00-1 page 2
Information and repair Instructions for the Automatic Gearbox 001 ....................... 00-2 page 1
- Information on the Automatic Gearbox 001 ....................................................... 00-2 page 1
- Repair instructions .................................................................................... 00-2 page 1
- Explanation of the terms used in this workshop manual. ........................................ 00-2 page 4
01 – Self-diagnosis, Electrical Test

Function of Self-diagnosis ........................................................................... 01-1 page 1
- Function of Self-diagnosis ............................................................................ 01-1 page 1
- Self-diagnosis technical data ........................................................................ 01-1 page 3
Electric/Electronic Components and Fitting Locations ...................................... 01-2 page 1
- Vehicle components .................................................................................. 01-2 page 1
- Electric/electronic components of the gearbox ................................................... 01-2 page 5
Performing self-diagnosis ............................................................................ 01-3 page 1
- Test conditions ......................................................................................... 01-3 page 1
- Work sequence ........................................................................................ 01-3 page 1
- Overview of selectable functions .................................................................... 01-3 page 2
- Interrogating and erasing fault memory ............................................................ 01-3 page 2
Fault Table and Initiating Basic Setting .......................................................... 01-4 page 1
- Fault table .............................................................................................. 01-4 page 1
- Initiating basic setting ................................................................................. 01-4 page 4
Reading measured value block ..................................................................... 01-5 page 1
- List of display groups ................................................................................. 01-5 page 1
- Test table ............................................................................................... 01-5 page 2
Inspecting the solenoid valves and shift elements while driving ........................... 01-6 page 1
- Solenoid valves and position of the shift elements ............................................... 01-6 page 1
Electrical Test ........................................................................................... 01-7 page 1
- Test procedure ......................................................................................... 01-7 page 1
- Check the wiring between the automatic gearbox control unit -J217- and the gearbox .... 01-7 page 6
32 – Torque Converter
Torque Converter ....................................................................................... 32-1 page 1
- Identification of the torque converter ............................................................... 32-1 page 1
- Draining the torque converter ........................................................................ 32-1 page 1
- Removing and installing gasket ring for torque converter ....................................... 32-1 page 1
- Installing the torque converter ....................................................................... 32-1 page 2
37 – Control, housing
Checking shifting points ............................................................................. 37-1 page 1
Measure limit speed of the hydraulic converter ................................................. 37-2 page 1
Fault finding ............................................................................................. 37-3 page 1
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- Before fault finding .................................................................................... 37-3 page 1

- Safety measures ...................................................................................... 37-3 page 1
- Fault finding table ..................................................................................... 37-3 page 2
Inspecting gearshift mechanism ................................................................... 37-4 page 1
- Inspecting gearshift mechanism .................................................................... 37-4 page 1
- Inspecting and adjusting the selector lever control cable ....................................... 37-4 page 1
Removing and Installing Shift Mechanism ...................................................... 37-5 page 1
- Removing and Installing Shift Mechanism ........................................................ 37-5 page 1
- Removing and installing the selector lever control cable ........................................ 37-5 page 3
- Removing and installing the selector lever grip ................................................... 37-5 page 5
Disassembling and assembling the gearshift mechanism ................................... 37-6 page 1
- Adjusting latch spring with roller .................................................................... 37-6 page 3
- Removing and installing selector lever lock solenoid -N110- ................................... 37-6 page 3
Removing and installing the gearbox ............................................................. 37-7 page 1
- Removing ............................................................................................... 37-7 page 1
- Installing ................................................................................................ 37-7 page 7
Checking and topping up ATF level ............................................................... 37-8 page 1
- Inspecting ATF level .................................................................................. 37-8 page 1
- Topping up ATF ....................................................................................... 37-8 page 2
- Replacing ATF ......................................................................................... 37-8 page 3
Disassembling and assembling the gearbox .................................................... 37-9 page 1
- Gearbox with shift elements ......................................................................... 37-9 page 1
- Removing and installing ATF radiator and ATF filler tube ...................................... 37-9 page 2
Disassembling and assembling planetary gear - Summary of components ............. 37-10 page 1
- I - Removing and installing ATF pump up to large sun gear ................................... 37-10 page 2
- II - Removing and installing cover for gearbox housing up to the drive gear ................ 37-10 page 3
Disassembling and assembling planetary gear - Assembly sequence .................... 37-11 page 1
- Disassembling planetary gear ....................................................................... 37-11 page 1
- Assembling planetary gear .......................................................................... 37-11 page 9
Adjusting work on planetary gear .................................................................. 37-12 page 1
- Overview ............................................................................................... 37-12 page 1
- Adjusting reverse gear-brake -B1- ................................................................. 37-12 page 2
- 2. Adjust 2nd and 4th gear-brake -B2- ............................................................ 37-12 page 4
- Setting clutch clearance .............................................................................. 37-12 page 6
38 – Wheels, Control
Disassembling and assembling the ATF pump ................................................. 38-1 page 1
Disassembling and assembling overrunning clutch ........................................... 38-2 page 1
1. Disassembling and assembling 1st through 3rd gear clutch -K1- ....................... 38-3 page 1
Disassembling and assembling the reverse gear-clutch -K2- ............................... 38-4 page 1
Disassembling and assembling 3rd and 4th gear-clutch -K3- ............................... 38-5 page 1
Disassembling and assembling the reverse gear-brake -B1- ................................ 38-6 page 1
Disassembling and assembling the piston for 2nd and 4th gear-brake -B2- ............. 38-7 page 1
Removing and installing slide valve body - Summary of components .................... 38-8 page 1
- Removing and installing ATF strainer .............................................................. 38-8 page 3
- Solenoid valve -N93- .................................................................................. 38-8 page 3
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II S00.5318.02.20
- Removing and installing retaining plate with solenoid valves -N88- through -N92- ......... 38-8 page 4
Disassembling and assembling the parking position ......................................... 38-9 page 1
39 – Final drive, differential

Replacing flange shaft gasket rings ............................................................... 39-1 page 1
Disassembling and assembling the final drive .................................................. 39-2 page 1
- Repair overview of the final drive ................................................................... 39-2 page 1
- Disassembling and assembling the input shaft ................................................... 39-2 page 2
- Disassembling and assembling the differential ................................................... 39-2 page 7
Adjusting the final drive ............................................................................. 39-3 page 1
- Overview of adjusting works ......................................................................... 39-3 page 1
- Adjusting works when replacing individual components ........................................ 39-3 page 2
- Adjusting the differential gear ........................................................................ 39-3 page 2
- Adjusting the input shaft .............................................................................. 39-3 page 4
Edition 04.05 Table of Contents III

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Table of Contents Edition 04.05

IV S00.5318.02.20
FABIA 2000 ³ Automatic Gearbox 001 00
00 – Technical Data
00-1 Technical Data for the

Gearbox
Identification of the gearbox

The „Automatic 4-speed gearbox 001“ engine is installed
in the Fabia 2000 ³ in combination with the 4 cylinder en-
gine. Assignment ⇒ 00-1 page 2.
Location on the gearbox

Identification characters and manufacturing data of
the gearbox -arrow-
Example:
ESK 18 07 0
I I I I
Identifica- Day Month Manufacturing
tion charac- year (2000)
ters
– The gearbox identification characters also appear on

the vehicle data stickers.
S37-0117
Edition 04.05 Technical Data for the Gearbox 00-1 page 1

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00 FABIA 2000 ³ Automatic Gearbox 001
Identification characters, aggregate assignment, ratios, capacities
Automatic gearbox 001

Gearbox Identification characters ESK GJF GJG
Manufac- from 07.00 12.02 12.02
tured through 11.02
Torque Converter Identification characters ACN ACN ACN
Slide valve body Identification characters CCC CCC CCC
Number of plates Inner Outer Inner Outer Inner Outer
Clutch -K1- 5 5 5 5 5 5
Clutch -K2- 2 2 2 2 2 2
Clutch -K3- 3 5 3 5 3 5
Brake -B1- 5 4 5 4 5 4
Brake band Brake -B2- (2nd gear) 57 + 36 57 + 36 57 + 36
stepped piston ∅ in mm
Brake -B2- (4th gear) 44 44 44
single piston ∅ in mm
Assignment Engine 1.4 ltr. - 55 kW 1.4 ltr. - 55 kW 1.4 ltr. - 55 kW
Ratios 1. Gear 2,875 2,875 2,875
2. Gear 1,510 1,510 1,513
3. Gear 1,000 1,000 1,000
4. Gear 0,726 0,726 0,726
Reverse 2,656 2,656 2,656
Intermediate gear No. of teeth Input gear 49 49 39
Output gear 53 53 42
Ratio 1,082 1,082 1,077
Final drive No. of teeth Drive pinion 20 20 20
Pinion final 81 81 81
drive
Ratio 4,050 4,050 4,050
Drive shaft flange ∅ 90 mm
Capacity
Planetary gear and final drive
Contents Automatic Gearbox 001

New filling 5.7 ltr.
(filled for life)
Lubricant ATF
Spare part no.:
G 052 990 A2
The oil filling is for the planetary gear and final drive to-
gether. Inspecting and filling ⇒ Chapter 37-8.
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00-2 Information and repair In-

structions for the Auto-
matic Gearbox 001
Information on the Automatic Gearbox

001
Information on this automatic gearbox can be found in
⇒ Self-study Programme No. 40; 4 speed automatic
gearbox 001.
Gearbox
The automatic 4 speed gearbox 001 is equipped with 4
hydraulically controlled forward gears. With the torque
converter lockup clutch closed the 3rd and 4th gear be-
come mechanically driven gears by bypassing the con-
verter slip.
Automatic Gearbox Control Unit -J217-

The control unit has two program options to meet the driv-
er's preference for sporty („SPORT“ program) or for eco-
nomic driving („ECO“ program).
These two programs are automatically selected in the
control unit.
Torque Converter
The torque converter is equipped with a torque converter
lockup clutch. The closing of the torque converter lockup
clutch is load and speed sensitive, and the torque con-
verter lockup clutch can drive the 3rd and 4th gears me-
chanically (without slip).
ATF
The ATF is filled for life. The ATF need not be changed
within the scope of servicing.
Only use ATF with spare part number
G 052 990 A2
if ATF needs to be added.
The ATF oil filling is for the planetary gear and final drive
together. Inspecting and filling ⇒ Chapter 37-8.
Repair instructions
Scrupulous care and cleanliness as well as the proper
tools are essential requirements for carrying out proper
and successful gearbox repairs. Obviously, the generally
valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair op-
erations - which are otherwise listed several times at nu-
merous points in the workshop manual - are summarized
here. They apply to this workshop manual.
Edition 04.05 Information and repair Instructions for the Automatic Gearbox 001 00-2 page 1
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Special tools
The composition of the special tools used in the work-
shop manual is listed in binder ⇒ Workshop Equipment
Catalogue.
Gearbox
♦ Do not run the engine or tow the vehicle when the oil
pan of the gearbox has been removed or without ATF
filling.
♦ When replacing the automatic gearbox check the
ATF, if necessary top up ⇒ Chap. 37-8. Capacities
and specification ⇒ Chap. 00-1.
♦ Secure the torque converter against dropping out
when the gearbox is removed.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Before installing the gearbox check the fitting dimen-
sion of the torque converter ⇒ Chap. 32-1.
♦ When installing pay attention to the correct position of
the dowel sleeves.
♦ Place removed parts on a clean surface and cover.
Use foil and paper. Do not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting.
O-rings, gasket rings, gaskets

♦ Always replace O-rings, gaskets and gasket rings.
♦ Before installing the gasket rings coat the outer cir-
cumference and sealing lips with ATF.
♦ Before inserting the O-rings coat with ATF to prevent
the rings being squashed during installation.
♦ Never use other lubricants in the ATF area.
♦ After installation check ATF level, if necessary correct.
Sealant
♦ Clean contact surfaces thoroughly and apply sealant
-D 176 404 A2-.
♦ Pay attention to the sell-by-date of the sealant.
♦ After applying the sealant screw the parts within 5
minutes.
♦ After installing, allow the sealant to dry for about 30
minutes. Only then may ATF be filled in.
Locking elements
♦ Do not over-extend the circlips, if necessary replace.
♦ Circlips must be positioned in the base of the groove.
♦ Replace roll pins. Fitting position: slot longitudinally to
power flow.
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Bolts, nuts
♦ Slacken and tighten nuts and bolts for attaching cov-
ers and housings diagonally across.
♦ Do not twist particularly sensitive parts - e.g. the slide
valve body - and slacken and tighten diagonally
across in stages.
♦ Tightening torques apply for non-oiled nuts and bolts.
♦ Clean the thread of the screws that are inserted with a
locking agent with a wire brush. Subsequently insert
screws with AMV 185 101 A1.
♦ Replace the self-locking screws and nuts.
Bearings
♦ Insert bearing in gearbox with ATF.
♦ Insert the axial needle bearing in the correct fitting po-
sition ⇒ Chap. 37-10.
♦ Before inserting heat the inner rings of the tapered-
roller bearing to approx. 100°C.
♦ Do not mix up the outer and inner races of bearings of
the same size.
♦ Always jointly replace tapered-roller bearings on the
same shaft and use products of the same manufactur-
er.
Piston rings
♦ Do not overwind when removing and installing.
Shims
♦ Gauge shims at several points with a micrometer. Dif-
ferent tolerances allow to measure the required thick-
ness for each washer very precisely.
♦ Inspect for burrs and damage. Install only shims which
are in perfect condition.
Inner plates
♦ Place new inner plates in ATF for 15 minutes before
installing.
Slide valve body

♦ The slide valve body must be replaced if the shift ele-
ments are burnt (plates).
Clutches
♦ The clutches can be dismantled, assign defective
parts (e.g. outer and inner plates) according to their
gearbox identification characters.
♦ Before installing the piston moisten the sealing lips
and gasket rings with ATF.
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♦ After fitting it must be possible to turn the piston by

hand in the clutches or brakes in both directions -ar-
rows-.
♦ If this is not the case, the sealing lips or gasket rings
may block or be damaged.
– If this defect occurs remove the piston.

– Check or replace the sealing lips or gasket rings for
damage, as necessary.
– Install the piston again and check again.
Brakes N38-0127
♦ Do not forcefully over-extend brake band -B2-.

♦ After removing secure the brake band against spread-
ing open, e.g. with a self-adapted wire hanger -A-.
Self-diagnosis
♦ Before repairing the automatic gearbox try to deter-
mine the origin of the damage as accurately as possi-
ble using self-diagnosis ⇒ Rep. Gr. 01.
A
Explanation of the terms used in this
workshop manual.
The following explanations are only related to this assem-
bly: Automatic Gearbox 001. They do not claim to be
generally applicable. Further information on these terms N38-0109
can be found in ⇒ Self-study Programme No. 40; 4-
speed Automatic Gearbox 001.
ATF (Automatic Transmission Fluid)

Gear oil for automatic gearbox
ATF-pump
Gear pump driven by the torque converter.
Brakes
They hold rotating parts in the gearbox. Automatic Gear-
box 001 is fitted with a band and a plate brake. As op-
posed to the clutches the brakes are supported on the
gearbox housing.
Torque Converter
Transfers the engine torque to the automatic gearbox and
serves as an hydraulic starting clutch. The torque con-
verter also includes the torque converter lockup clutch.
Self-diagnosis
The capability of the control unit to:
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♦ recognize faults,
♦ react to faults,
♦ store faults,
♦ Determine measured values and to display them in
the measured value block.
Free wheel/Stator
Ensures the torque increase in the torque converter when
starting.
Free wheel/Gearbox
Simplifies the technical effort of the gearshift without trac-
tion interruption and ensures a uniform gearshift quality.
Gearbox speed sender -G38-

The sender determines the speed of clutch -K3- and
sends it to the automatic gearbox control unit.
Vehicle speed sender -G68-

The sender determines the speed of the output gear and
sends it to the automatic gearbox control unit (not the
speedometer).
Gearbox oil temperature sender -G93-

Monitors the ATF temperature.
Clutches
Together with the brakes they shift the individual gears.
Selector lever lock solenoid -N110-

Located in the gearshift mechanism close to the selector
lever. Prevents the (unintentional) shifting of the selector
lever from positions „P“ and „N“, as long as the brake
pedal is not pressed.
Solenoid valves
Open and shut the oil galleries to the clutches and
brakes.
Multi-function switch -F125-

Electric switch with different functions. Further informa-
tion on this can be found in ⇒ Self-study Programme
No. 40; 4 speed Automatic Gearbox 001.
Emergency running mode

»Status of the control unit«, to ensure further safe opera-
tion in the event of a detected faults, to protect the gear-
box from damage and to thereby restrict the driving
behaviour as little as possible.
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Parking position
When the vehicle is standing the parking gear is block
mechanically thereby protecting the vehicle against (un-
intentional) rolling off.
Planetary gear
The mechanical part of the automatic gearbox that is
switched via clutches and brakes without power flow in-
terruption.
Slide valve body

Located below the gearbox and is surrounded by the oil
pan of the gearbox. Its valves regulate the hydraulic pres-
sure and distribute it via the oil galleries to the gearshift
elements (clutches and brakes).
Automatic Gearbox Control Unit -J217-

The electronic control unit determines the shifting points.
The function of the gearbox is monitored via self-diagno-
sis. If components or sensors fail an emergency running
programme is activated to maintain driveability.
LC (torque converter lockup clutch)

Mechanically transmits the engine torque to the gearbox.
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01 – Self-diagnosis, Electrical Test
01-1 Function of Self-diagno-

sis
Function of Self-diagnosis
The control of the automatic gearbox is electronic/hy-
draulic.
The term „self-diagnosis“ is related to this electric/elec-
tronic control.
Additionally required information means

♦ Self-study programme No. 40
Control unit -J217 with driving situation circuits

(Fuzzy Logic)
The driving situation and road resistance dependent
shifting point determination occurs automatically.
Advantages:
♦ shifting occurs with a focus on economic consumption
♦ greatest engine power is always available
♦ individual adaptation of the shifting points to all driving
situations
♦ shifting points modified as required
Functions of gearbox control unit

The automatic gearbox control unit -J217- receives infor-
mation from components that influence the shift controls
and sends this information to the slide valve body with the
solenoid valves which drives the shift elements through
the hydraulic shift controls.
The control unit is equipped with a fault memory to be
able to rapidly determine the origin of the damage if an
electric/electronic component fails or in the event of a line
interruption. Faults are detected by eletric signals and are
stored in the fault memory.
Fault recognition of the gearbox control unit

The control unit detects faults while the vehicle is being
operated and stores them in the fault memory ⇒ Chap.
01-4.
After analysing the information it makes a distinction be-
tween sporadic and currently present (static) faults and
stores them.
If the fault is not indicated for a given time or over a long
driving distance is becomes a sporadic fault.
A fault is also sporadic if the fault memory is not erased
after repair.
Edition 07.00 Function of Self-diagnosis 01-1 page 1

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During fault interrogation sporadic faults are displayed

using -V.A.G 1552- as „sporadically occurring faults“.
„SP“ appears on the right of the display.
If after a given period or a long driving distance this spo-
radic fault no longer occurs, the fault is erased from the
fault memory.
Fault memory
The fault memory of the control unit is a „permanent
memory“. Stored faults are not erased if the control unit is
dead. If for a long period of time e.g. the vehicle battery is
disconnected or if the control unit plug was disconnected
the fault memory content is preserved.
Safety function of the gearbox control unit

If faults occur while driving, the control unit may activate
replacement functions or emergency programmes.
These may influence the shifting function and quality.
In emergency running mode, the 3rd gear and reverse
gear can be engaged by activating the selector lever.
If the fault occurs in „P“, „N“ or „R“, „P“, „N“ or „R“ will also
be activated in emergency running mode.
The gearbox will be activated in emergency runing mode
until the fault is stored or if it is not detected by the control
unit over a given period of time.
Faults that may result in emergency running

mode
Line interruption, short-circuit, defective electric or hy-
draulic components.
Safety measures
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there. If the test and measuring devices are operated
from the passenger seat the passenger could be in-
jured by the release of the passenger airbag in the
event of an accident.
Vehicle system tester -V.A.G 1552-

Functions, detected or performed by the vehicle system
tester -V.A.G 1552- ⇒ Chap. 01-3.
Electrical faults that influence the driveability can be de-
termined with vehicle system tester -V.A.G 1552-.
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Self-diagnosis technical data
Memory
♦ Permanent memory yes
♦ Volatile memory no
Data output
♦ Vehicle system test yes
♦ Flashing code output no
Final control diagnosis no

Basic setting yes ⇒ Chap. 01-4
Coding control unit no
Reading measured value yes ⇒ Chap. 01-5
block
Electric/Electronic compo- ⇒ Chap. 01-2
nents and fitting locations
Edition 07.00 Function of Self-diagnosis 01-1 page 3

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01-1 page 4 Function of Self-diagnosis Edition 07.00

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01-2 Electric/Electronic Components and Fitting Locations
Vehicle components
Gearbox components ⇒ 01-2 page 5
1 - Engine control unit

T Fitting location and removing 1 2
and installing ⇒ Fig. 1 in
01-2 page 2
T Signal transfer occurs over
the data BUS drive
Note
If the control units of the engine
or gearbox are replaced the sys-
tem must be put into basic set-
ting ⇒ Chap. 01-4 3
2- Selector lever position dis-
play -Y6- 4
T Fitting location ⇒ Fig. 7 in 9
01-2 page 4
T Signal transfer occurs over
the data BUS drive
3- Diagnostic connection
01-2 page 2
5
4- Selector lever lock solenoid
-N110-
T Fitting location and removing
and installing ⇒ Chap. 37-2
T is switched by the vehicle 6
voltage control unit -J519-
5- Brake light switch -F-
01-2 page 3
T Signal transfer occurs via the
data BUS drive of the ABS S01-0102
with EDL control unit -J104-
6- Relay for starter interlock switch -J207-
T Fitting location ⇒ Fig. 5 in 01-2 page 3
T is switched by the vehicle voltage control unit -J519-
7- Accelerator pedal position sender -G79-
T Fitting location and removing and installing ⇒ Fig. 3 in 01-2 page 2
T generates the kick-down signal
T Signal transfer occurs over the data BUS drive of the engine control unit
8- Gearbox
T Electric/electronic components of the gearbox ⇒ 01-2 page 5
9- Automatic Gearbox Control Unit -J217-
T Fitting location ⇒ Fig. 6 in 01-2 page 3
T removing ⇒ Fig. 6 in 01-2 page 3
T Control unit is checked by self-diagnosis ⇒ Chap. 01-3
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Fitting locations
Fig. 1: Engine control unit
Fitting location: The control unit is located at bulkhead.
Removing and installing the control unit ⇒ Engine,
Fuel Injection; Rep. Gr. 24
S24-0373
Fig. 2: Diagnostic connection

Fitting location: The diagnostic connector is located be-
hind the storage area -arrow- on the driver's side.
S01-0104
Fig. 3: Accelerator pedal position sender -G79-

Fitting location: The accelerator pedal position sender
-G79- -arrow- is a component part of the gas pedal.
The accelerator pedal position sender -G79- generates
the „Kick-down signal“, when the accelerator pedal is
suddenly pressed down fully.
For self-diagnosis
Signal can only be checked in the measured value block
⇒ Chap. 01-5.
Removing and installing accelerator pedal position
sender -G79-
⇒ Engine, Mechanics; Rep. Gr. 20 S01-0105
01-2 page 2 Electric/Electronic Components and Fitting Locations Edition 07.00

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Fig. 4: Brake light switch -F-
Fitting location: The brake light switch -F- -arrow- is locat-
ed in the foot controls.
For self-diagnosis
Signal can be checked in the measured value block
⇒ Chap. 01-5.
Removing and installing the brake light switch
⇒ Running gear; Rep. Gr. 45
S01-0107
Fig. 5: Relay for starter interlock switch -J207-

Fitting location: The relay is located on the relay carrier
-1- above the vehicle voltage control unit -2-.
1
The relay carrier is located behind the storage area on
the driver's side.
The relay is identified with number „53“.
Removing and installing the relay
– Remove the storage area on the driver's side ⇒ Body 2

Work; Rep. Gr. 68.
– Remove the relay from the relay carrier.
S01-0108
Fig. 6: Automatic Gearbox Control Unit -J217-

The control unit -arrow- is located behind the battery on
the battery tray.
Removing the control unit
– Switch off ignition, open engine compartment cover.

– Unlock the multi-pin connector and unplug it from the
control unit.
S01-0111

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– Release the two screws -arrows- and remove the con-

trol unit.
The installation occurs in reverse order.
– Initiate basic setting ⇒ Chap. 01-4.

– Perform self-diagnosis ⇒ Chap. 01-3.
S01-0109
Fig. 7: Selector lever position indicator -Y6-

Fitting location: in the dash panel insert
Removing and installing: ⇒ Electrical System;
Rep. Gr. 90
For self-diagnosis:
In the event of emergency running mode and if the control
unit is operational all segments of the selector lever posi-
tion indicator -Y6- light up in the dash panel insert.
In the event of emergency running mode and if the control
unit fails there is no indication of the selector lever posi-
tions.
S01-0103
S01-0108

S00.5318.00.20
Electric/electronic components of the gearbox
1 - 6 Nm
2 - Wiring loom 1
3 - Vehicle speed sender -G68-
T with connection cable 2
01-2 page 6 3
T is checked by self-diagnosis
4
4 - 6 Nm
5 - 6 Nm 5
6 - Gearbox speed sender -G38-
T with connection cable 6
01-2 page 6
7
T is checked by self-diagnosis
7 - Gearbox
8 - Wiring loom
T for the solenoid valves and
gearbox oil temperature
8
sender -G93-
01-2 page 5
9 - Multi-function switch -F125- 10
T adjust ⇒ Fig. 10 in 01-2
page 6 9
T is checked by self-diagnosis 12 10
10 - 3 Nm 11
11 - Lever
T for gearshift shaft S37-0059
12 - 17 Nm
Fitting locations
Fig. 8: Wiring loom for the solenoid valves and
gearbox oil temperature sender -G93-
Fitting location: The wiring loom is located in the oil pan
under the slide valve body.
Removing and installing the wiring loom
The wiring loom can be replaced with the gearbox mount-
ed without having to remove the slide valve body.
S37-0066

S00.5318.00.20
– Drain ATF ⇒ Chap. 37-8.

– Removing the oil pan ⇒ Chap. 38-2.
– Disconnect the plug connection at gearbox.
1
– Unlock the connector -arrows- and remove from gear- 2
box housing.
– Unclip gearbox oil temperature sender -G93- -3-.
3
– Release plug connection -4- from the solenoid valve 6
-N93-.
– Disconnect the plug connection -1- for the solenoid
valves.
– Unhook the wiring loom from the holder -2-. 4
S37-0083
– Clean the sealing surface of the oil pan at the gearbox
and at the oil pan and coat with sealant:
D176 404 A2
A B
when installing ⇒ Chap. 37-11.
– Top up ATF ⇒ Chap. 37-8.

Tightening torques:
Oil pan at gearbox: 8 Nm
Fig. 9: Gearbox speed sender -G38- and vehicle
speed sender -G68-
Fitting location: The sender is located at the top of the
gearbox.
-A- -G38- with connection cable
S37-0065
-B- -G68- with connection cable
Removing and installing sender
– Disconnect the plug connection at wiring loom.

– Remove screw, pull out sender.
– Replace O-ring.
1
2
3

D
N
R
P
– Tighten screw to 6 Nm.

Fig. 10: Adjust multi-function switch.
Requirements
• Adjustment of the selector lever control cable O.K.

⇒ Chap. 37-4 A
• Selector lever in „N“
• Screws -arrows- released
– Insert a 4 mm drill bit -A- through the gearshift lever in
the adjusting hole of the multi-function switch.
– Tighten screws -arrows- on the multi-function switch
in this position to 3 Nm.
– Remove drill bit. S37-0060

S00.5318.00.20
01-3 Performing self-diagnosis

Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3-
Test conditions
• Battery voltage at least 11.5 V
• Earth connection to engine and gearbox O.K.
• Fuses according to current flow diagram O.K.
Work sequence
The connector is located behind the storage area on the
driver's side.
– Unclip the cover and fold down.

– Connect vehicle system tester -V.A.G 1552- with the
diagnostic cable -V.A.G 1551/3-
Once the vehicle system tester has been connected:
V.A.G 1552
– Switch on ignition or start engine depending on the
desired function.
V.A.G 1551/3
Note
♦ If because of an input error „data transfer fault“ is dis- S01-0087
played, remove the cable from the vehicle system
tester, re-connect and repeat the steps.
Vehicle system test HELP
♦ If one of the following messages appears in the dis- The control unit does not respond
play, carry out fault finding as specified in the fault
finding program diagnostic cable. ⇒ Current flow dia-
grams, fault finding electrical system, fitting locations
or ⇒ operating instructions of the vehicle system test-
er. Vehicle system test HELP
Fault in communication set-up

K cable does not connect to earth

K cable doest not connect to pos. term.
– Operate the vehicle system tester by following the in-
dication on the display:
Read-out on display: Enter address word XX
– Press 0 and 2 for „address word“ 02 and confirm the
entry with Q .
001927731H AG4 Gearbox 001 JEG2944 ->
The vehicle system tester -V.A.G 1552- displays the con-
trol unit identification, e. g.:
Control unit identification
Depending on the fitting status (program status) the con-
trol unit may indicate a different control unit identification
Edition 07.00 Performing self-diagnosis 01-3 page 1

S00.5318.00.20
than the one shown in this example. Assignment of the

control unit ⇒ Spare part catalogue.
♦ 001927731H = Part No. of the control unit (for current
control unit version see spare parts catalogue)
♦ AG4 Gearbox 001 = Automatic gearbox 4 speed 001
♦ 2944 = Data status (Software version of the control
unit)
– Press →.
Read-out on display: Select function XX
– Further procedure, see repair sequences.
– After pressing HELP an overview of the possible func-
tions is displayed.
Overview of selectable functions
Operation Page
01 - Interrogating control unit ver- ⇒ 01-3 page 1
sion ⇒ Performing self-diag-
nosis
02 - Interrogating fault memory ⇒ 01-3 page 2
04 - Initiating basic setting ⇒ Chap. 01-4
05 - Erasing fault memory ⇒ 01-3 page 2
06 - Ending output
08 - Reading measured value ⇒ Chap. 01-5
block
Interrogating and erasing fault memory

Interrogating fault memory

– Connect vehicle system tester -V.A.G 1552-. Switch
on the ignition and select the gearbox control unit with
„Address word“ 02 ⇒ 01-3 page 1.
– Press 0 and 2 for the function „Interrogate fault
memory“ and confirm the entry with Q .
X faults detected
The display shows the number of faults stored in the
memory or „ no fault detected! “. will be displayed.
If no fault is stored in the memory:
– Select function 06 „End output“ and confirm entry with

Q.
If one or more faults are stored in the memory:
– Press →.
01-3 page 2 Performing self-diagnosis Edition 07.00

S00.5318.00.20
Read-out of fault number on display, e.g.:
->
Fault number: 00258 035
– Press →.
Read-out of fault source with fault type on display, e.g.: Solenoid valve 1 -N88 ->
Short-circuit to earth
– Press →.
The stored faults are displayed in sequence.

Q.
– Refer to the fault table to remove the indicated faults
⇒ Chap. 01-4.
Note
During testing and installation other control units may
also detect faults, e.g. pulled-out connectors. This is why
you must conclude the self-diagnosis by interrogating
and erasing the fault memories of all control units. For
this you must proceed as follows:
– Press 0 twice for address word „Automatic test se-

quence“ and confirm entry with Q .
The -V.A.G 1552- sends all known address words in se-
quence.
Erasing fault memory

Test conditions
• Fault eliminated
• Fault memory interrogated ⇒ 01-3 page 2.
Note
After fault elimination the fault memory must again be in-
terrogated and subsequently erased.
– Press 0 and 5 for the function „Erase fault memory“

and confirm the entry with Q .
Vehicle system test ->
Read-out on display: Fault memory erased
Note
If the ignition has been switched off between „interrogate
fault memory“ and „erase fault memory“, the fault memo-
ry will not be erased.

Q.
– Perform a test drive. Again interrogate the fault mem-
ory. No fault must be displayed.
Note
Comply with the safety instructions for test drives
⇒ Chap. 01-1.
Edition 07.00 Performing self-diagnosis 01-3 page 3

S00.5318.00.20
01-3 page 4 Performing self-diagnosis Edition 07.00

S00.5318.00.20
01-4 Fault Table and Initiating Basic Setting
Fault table
Note
♦ The fault table is ordered according to the 5-digit fault code on the left.
♦ If parts are output as faulty: First check the cables and connectors to these parts as well as the earth leads of the
system by referring to the current diagram. Only if no fault is detected here should the part be replaced. This applies
in particular for faults that are output as „sporadically occurred“(SP) faults.
♦ If the display of the vehicle system tester -V.A.G 1552- reads „Documentation“, the required text is to be found in
the fault table according to the fault code.
Read-out on -V.A.G 1552- Possible cause of fault Rectifying fault

00258 ♦ Open circuit/ ♦ Line interruption – Reading measured value
Solenoid valve 1 -N88- Short-circuit to ♦ Line short-circuit to earth or block, display group number
pos. term. positive 004 ⇒ Chap. 01-5.
♦ Short-circuit to ♦ Solenoid valve 1 -N88- de- – Performing electrical test, test
earth fective step 5 ⇒ Chap. 01-7.
00281 ♦ No signal ♦ Line interruption or short-cir- – Reading measured value
Vehicle speed sender cuit to earth block, display group number
-G68- ♦ Vehicle speed sender -G68- 003 ⇒ Chap. 01-5.
defective – Performing electrical test, test
step 3 ⇒ Chap. 01-7.
– Replacing vehicle speed
sender -G68- ⇒ Chap. 01-2.
Edition 07.00 Fault Table and Initiating Basic Setting 01-4 page 1
S00.5318.00.20

00293 ♦ undefined switch ♦ Line interruption – Reading measured value
Multi-function switch status ♦ Multi-function switch -F125- block, display group number
-F125- ♦ No signal not adjusted 004 ⇒ Chap. 01-5.
♦ Multi-function switch -F125- – Adjusting multi-function switch
defective -F125- ⇒ Chap. 37-4.
– Performing electrical test, test
00296 ♦ Short-circuit to ♦ Line interruption – Reading measured value
Kick-down switch -F8- earth ♦ Accelerator pedal position block, display group number
sender -G79- defective 004 ⇒ Chap. 01-5.
♦ Data BUS defective – Inspecting accelerator pedal
position sender -G79-
⇒ Engine, Fuel Injection;
Rep. Gr. 24.
– Testing data BUS ⇒ Electrical
system; Rep. Gr. 90.
00297 ♦ No signal ♦ Line interruption – Reading measured value
Gearbox speed send- ♦ Gearbox speed sender block, display group number
er -G38- -G38- defective 001 ⇒ Chap. 01-5.
Gearbox oil tempera- Short-circuit to ♦ Gearbox oil temperature block, display group number
ture sender -G93- pos. term. sender -G93- defective 002 ⇒ Chap. 01-5.
step 11 ⇒ Chap. 01-7.
00350 ♦ Outlet does not ♦ Line interruption – Check wiring and plug con-
Earth return Modula- connect/Short- ♦ Automatic gearbox control nections according to the cur-
tion valves circuit to positive unit -J217- defective rent flow diagram ⇒ Current
Flow Diagrams, Electrical
Fault Finding and Fitting Lo-
cations.
– Replacing control unit
⇒ Chap. 01-2.
– Put system in basic setting
⇒ 01-4 page 4
00526 ♦ Short-circuit to ♦ Line interruption – Reading measured value
Brake light switch -F- positive terminal ♦ Brake light switch -F- defec- block, display group number
tive 004 ⇒ Chap. 01-5.
♦ Data BUS defective – Testing data BUS ⇒ Electrical
– Inspecting brake light switch
-F- ⇒ Running Gear;
Rep. Gr. 45.
Speed information ♦ Data BUS defective block, display group number
missing 001 ⇒ Chap. 01-5.
– Inspecting engine control unit
Rep. Gr. 01.
01-4 page 2 Fault Table and Initiating Basic Setting Edition 07.00
S00.5318.00.20

00545 ♦ Open circuit/ ♦ Line interruption or short-cir- – Reading measured value
Engine/gearbox elec- Short-circuit to cuit block, display group number
trical connection earth ♦ no connection engine/gear- 125 ⇒ Chap. 01-5.
♦ Short-circuit to box control unit – Inspecting engine control unit
positive terminal ♦ the signal for the ignition-tim- ⇒ Engine, Fuel Injection;
ing adjustment is not or in- Rep. Gr. 01.
correctly transmitted from
the engine to the gearbox
control unit
♦ Data BUS defective – Put system in basic setting
⇒ 01-4 page 4
00652 ♦ Implausible sig- ♦ electric/hydraulic fault – While driving determine in
Gear monitoring nal ♦ Clutch or slide valve body which gear the fault occurs.
defective – Carry out fault finding accord-
ing to fault finding table
⇒ Chap. 37-3.
Accelerator pedal po- ♦ Accelerator pedal position block, display group number
sition sender -G79- sender -G79- defective 003 ⇒ Chap. 01-5.
♦ Data BUS defective – Testing data BUS ⇒ Electrical
– Inspecting accelerator pedal
position sender -G79-
Rep. Gr. 24.
01166 ♦ Implausible sig- ♦ Line interruption – Inspecting engine control unit
Signal for engine nal ♦ the signal for the engine ⇒ Engine, Fuel Injection;
torque torque is not or incorrectly Rep. Gr. 01.
transmitted from the engine – Testing data BUS ⇒ Electrical
to the gearbox control unit system; Rep. Gr. 90.
01192 ♦ Clutch for torque ♦ Line interruption – Reading measured value
Clutch for torque con- converter lockup ♦ Lockup clutch slips block, display group number
verter lockup defective 003 ⇒ Chap. 01-5.
♦ Solenoid valve 4 -N91- de-
♦ mechanical fault fective – Performing electrical test, test
♦ Slide valve body defective step 8 ⇒ Chap. 01-7.
01236 ♦ Short-circuit to ♦ Line interruption or short-cir- – Reading measured value

Selector lever lock so- earth cuit to earth block, display group number
lenoid -N110- ♦ Open circuit/ ♦ Selector lever lock solenoid 004 ⇒ Chap. 01-5.
Short-circuit to -N110- defective – Inspecting vehicle voltage
pos. term. ♦ Vehicle voltage control unit control unit -J519-
-J519- defective ⇒ Electrical System;
Rep. Gr. 90.
– Replacing selector lever lock
solenoid -N110- ⇒ Chap. 37-
6.
01312 ♦ defective ♦ Data BUS wires and plug – Testing data BUS ⇒ Electrical
Data BUS drive ♦ no communica- connections defective system; Rep. Gr. 90.
tion ♦ Control units on data BUS – Inspecting control units at
defective or incorrectly cod- data BUS ⇒ Engine, Fuel In-
ed jection; Rep. Gr. 01
S00.5318.00.20

01314 ♦ no communica- ♦ Data BUS wires and plug – Inspecting engine control unit
4AV Control unit tion connections defective ⇒ Engine, Fuel Injection;
♦ wrong equip- ♦ Fault in system engine Rep. Gr. 01.
ment ♦ Engine control unit possibly – Testing data BUS ⇒ Electrical
incorrectly coded system; Rep. Gr. 90.
01316 ♦ no communica- ♦ Data BUS wires and plug – Inspecting ABS control unit
Brake control unit tion connections defective ⇒ Running Gear;
♦ Fault in ABS system Rep. Gr. 45.
65535 ♦ Control unit de- ♦ Automatic gearbox control – Replacing control unit
fective unit -J217- defective ⇒ Chap. 01-2.
– Put system in basic setting
⇒ 01-4 page 4.
Only after having determined the possible cause of the fault and having eliminated the following faults:
♦ mechanical fault
♦ hydraulic fault
♦ or affected electric/electronic components and wiring
should the automatic gearbox control unit -J217- be replaced ⇒ Chap. 01-2, and the system be put in basic setting
⇒ 01-4 page 4.
Initiating basic setting

Perform the basic setting after the following repairs:
♦ Engine replacement
♦ Removing and installing the gearbox
♦ Replacing or coding the engine control unit
♦ Replacing the accelerator pedal position sender -G79-
♦ Replacing the automatic gearbox control unit -J217-
– Connect vehicle system tester -V.A.G 1552-, enter

„address word“ 02 „gearbox electronics“ and keep
switching until „select function XX“ is displayed
⇒ Chap. 01-2
– Press 0 and 4 for the function „initiating basic set-
ting“.
Note
Do not activate the accelerator pedal yet.
Vehicle system test Q
Read-out on display: 04 - Basic setting
– Confirm the entry with Q.
Basic setting
Read-out on display:
Enter display group number XXX
– Press keys 0 , 0 and 0 .
– Confirm the entry with Q.
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System in basic setting 0->
This puts the system in basic setting.
– Depress accelerator pedal up to kickdown and main-

tain in this position for 3 seconds.
– → press.
– Release accelerator pedal again
S00.5318.00.20
S00.5318.00.20
01-5 Reading measured value

block
Work sequence
– Connect vehicle system tester -V.A.G 1552-. Switch

on the ignition and select the gearbox control unit with
„Address word“ 02 ⇒ Chap. 01-1.
– Press 0 and 8 for the function „Read measured val-
ue block“ and confirm with Q .
Reading measured value block
Enter display group number XXX
– Enter display group number ⇒ 01-5 page 1.
– Further procedure, see repair sequences.
List of display groups
Read-out on display (example) Display Display Denomination

group field
number
Reading measured value block 1 → 001 1 Vehicle speed sender -G68-
gearbox speed sender
20 km/h 1500 rpm 1520 rpm 1 2 -G38-
engine speed
3 gear engaged
4
Reading measured value block 2 → 002 1 Accelerator pedal value
2 solenoid valve 6 -N93- (ad-
0% 35 % 30.0 °C 12.5 V justment in %)
3 ATF temperature
4 battery voltage
Reading measured value block 3 → 003 1 Vehicle speed sender -G68-
accelerator pedal value
20 km/h 0% 1 4% 2 gear engaged
3 solenoid valve 4 -N91- (ad-
4 justment in %)
Reading measured value block 4 → 004 1 Selector lever position
2 multi-function switch
D 00001000 01000000 00000110 3 switch positions
4 shift outputs
Reading measured value block 125 → 125 1 Engine control unit at data
BUS
Engine 1 ABS 1 Combi 1 2 ABS control unit at data
BUS
3 dash panel insert at data
BUS
4 not assigned
Edition 07.00 Reading measured value block 01-5 page 1

S00.5318.00.20
If the nominal values are reached in all display fields:
– → press.
Select function XX
– Press 0 and 6 for the function „End output“ and con-
firm with Q .
Test table
Dis- Dis- Denomination Test conditions Display on Measures for deviations from nomi-
play play V.A.G. 1552 nal value
group field
numb
er
001 1 Vehicle speed while driving ...km/h The display in the dash panel insert and
sender -G68- the values on V.A.G. 1552 may differ
slightly from one another.
– Inspecting vehicle speed sender

-G68- ⇒ Chap. 01-7.
2 Gearbox speed with engine running .../min – Inspecting gearbox speed sender
sender -G38- while driving -G38- ⇒ Chap. 01-7.
3 Engine speed with engine running .../min The display in the dash panel insert and
the values on V.A.G. 1552 may differ
– Perform self-diagnosis of engine

control unit ⇒ Engine, Fuel Injec-
tion; Rep. Gr. 01.
– Testing data BUS ⇒ Electrical sys-

tem; Rep. Gr. 90.
4 gear engaged while driving – Inspecting solenoid valve ⇒ Chap.

Neutral 1 01-7.
Reverse (up 1
to approx. 10
km/h)
1 hydraulic 1
2 hydraulic 2
3 hydraulic 3H
3 mechanic 3M
4 hydraulic 4H
4 mechanic 4M
01-5 page 2 Reading measured value block Edition 07.00

S00.5318.00.20
group field
numb
er
002 1 Accelerator at stand- Idling 0....1 % When accelerating from idle to full throt-
pedal value still tle the %-value increases constantly.
Full throttle 90 % – Inspecting accelerator pedal posi-
Kickdown 99 % tion sender -G79- ⇒ Engine, Fuel
Injection; Rep. Gr. 23 oder 24.
– Perform basic setting ⇒ Chap. 01-4.
2 Solenoid valve at stand- Idling 0...25 % – Inspecting solenoid valve 6 -N93-
6 -N93- still Full throttle 88...100 % ⇒ Chap. 01-7.
3 ATF tempera- in idle ... °C – Inspecting gearbox oil temperature
ture the exact display of the sender -G93- ⇒ Chap. 01-7.
the ATF level is temperature only occurs
checked at a above approx. 30 °C.
temperature of
35...45 °C
4 Battery voltage at stand- min. 11.5 V – Testing voltage supply ⇒ Chap. 01-
still max. 14.4 V 7.
– Check battery ⇒ Electrical System;
Rep. Gr. 27.
003 1 Vehicle speed While driving ...km/h The display in the dash panel insert and
sender -G68- the values on V.A.G. 1552 may differ
– Inspecting vehicle speed sender

-G68- ⇒ Chap. 01-7.
2 Accelerator at stand- Idling 0...1 % When accelerating from idle to full throt-
pedal value still tle the %-value increases constantly.
Full throttle 90 % – Inspecting accelerator pedal posi-
Kickdown 99 % tion sender -G79- ⇒ Engine, Fuel
Injection; Rep. Gr. 23 oder 24.
– Perform basic setting ⇒ Chap. 01-4.
3 gear engaged while driving – Inspecting solenoid valve ⇒ Chap.
Neutral 1 01-7.
Reverse (up 1
to approx. 10
km/h)
1 hydraulic 1
2 hydraulic 2
3 hydraulic 3H
3 mechanic 3M
4 hydraulic 4H
4 mechanic 4M
4 Solenoid valve while driving – Inspecting solenoid valve 4 -N91-
4 -N91- hydraul. Gear 4...6 % ⇒ Chap. 01-7.
mech. Gear 94...96 %

S00.5318.00.20
group field
numb
er
004 1 Selector lever Inspecting selector lever – Multi-function switch -F125-
position in ⇒ Chap. 01-7.
P P
R R
N N
D D
3 3
2 2
1 1
2 Multi-function Inspecting selector lever – Multi-function switch -F125-
switch -F125- in ⇒ Chap. 01-7.
P 00000001
R 00000010
N 00000100
D 00001000
3 00010000
2 00100000
1 01000000
3 ignore first six positions
Kick-down sig- Kick-down signal – Inspecting accelerator pedal position
nal 7. Posi- available 1 sender -G79- ⇒ Engine, Fuel Injec-
tion tion; Rep. Gr. 23 oder 24.
not available 0
– Testing data BUS ⇒ Electrical sys-
tem; Rep. Gr. 90.
Brake light Brake – Inspecting brake light switch -F-
switch -F- 8. Posi- activated 1 ⇒ Running Gear; Rep. Gr. 45.
tion not activated 0

S00.5318.00.20
group field
numb
er
004 4 Solenoid valve 1. Posi- activated 1 – Inspecting solenoid valve 4 -N91-
4 -N91- for tion ⇒ Chap. 01-7.
lockup clutch not activated 0
Selector lever 2. Posi- engaged 1 – Inspecting selector lever lock sole-
lock solenoid tion noid -N110- ⇒ Chap. 37-6.
-N110- selector
lever in – Inspecting brake light switch -F-
„P“ ⇒ Running Gear; Rep. Gr. 45.
or in „N“
Activate switched off 0
brake or
selector
lever in
„R“, „D“,
„3, 2, 1“
Deactivation of 3. Posi- is switched 1 – Testing air conditioning system
air conditioning tion off ⇒ Air conditioning; Rep. Gr. 87.
is not 0 – Testing data BUS ⇒ Electrical sys-
switched off tem; Rep. Gr. 90.
Ignition-timing 4. Posi- switched on 1 – Perform self-diagnosis of engine
adjustment tion (only dis- control unit ⇒ Engine, Fuel Injec-
played when tion; Rep. Gr. 01.
shifting
gears) – Perform basic setting ⇒ Chap. 01-4.
switched off 0
Solenoid valve 5. Posi- activated 1 – Inspecting solenoid valve 3 -N90-
3 -N90- tion not activated 0 ⇒ Chap. 01-7.

S00.5318.00.20
group field
numb
er
125 1 Engine control Engine at data BUS 1 – Testing data BUS ⇒ Electrical sys-
unit not at data 0 tem; Rep. Gr. 90.
BUS
– Perform self-diagnosis of engine

control unit ⇒ Engine, Fuel Injec-
tion; Rep. Gr. 01.
2 ABS control ABS at data BUS 1 – Testing data BUS ⇒ Electrical sys-
unit not at data 0 tem; Rep. Gr. 90.
BUS
– Perform self-diagnosis of ABS

⇒ Running Gear; Rep. Gr. 45.
3 Dash panel in- Combi at data BUS 1 – Testing data BUS ⇒ Electrical sys-
sert not at data 0 tem; Rep. Gr. 90.
BUS
– Perform self-diagnosis of the dash

panel insert ⇒ Electrical System;
Rep. Gr. 90.
4 not assigned

S00.5318.00.20
01-6 Inspecting the solenoid

valves and shift elements
while driving
The solenoid valves and shift elements can be inspected
while driving in measured value block „08“, display group
„004“ (⇒ Chap. 01-5).
– Observe the safety instructions in ⇒ Chap. 01-1.

♦ The table indicates the activated solenoid valves -
N88-, -N89- and -N92- in the individual gears. They
control the position of the corresponding shift ele-
ments in the gears.
♦ Solenoid valve -N91- controls the modulation valve for
the lockup clutch.
♦ Solenoid valves -N90- and -N93- are valves that influ-
ence gearshifting indirectly to offer great shifting com-
fort. -N90- = time delay valve, -N93- = main pressure
valve (is not displayed in display group number 004).
Note
♦ The display on vehicle system tester -V.A.G 1552- is
8-digit (e.g.: 01000011).
♦ Only consider positions 1, 3, 7 and 8.
Test conditions
• Selector lever in position „D“

• Vehicle speed higher than 10 km/h
Solenoid valves and position of the shift elements
Solenoid valves Shift elements

Gear N91 Disregard display N92 N89 N88 K1 K2 K3 B1 B2 F LC
1 0 1 0 1 X X
2 0 1 1 1 X X
3H 0 0 1 0 X X
3M 1 0 1 0 X X X
4H 0 0 1 1 X X
4M 1 0 1 1 X X X
X = closed shift element

K1 = 1st through 3rd gear clutch
K2 = Reverse gear clutch
K3 = 3rd and 4th gear clutch
B1 = Reverse and 1st gear brake
B2 = 2nd and 4th gear brake
F = Free wheel
LC = Lockup clutch
Edition 07.00 Inspecting the solenoid valves and shift elements while driving 01-6 page 1
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01-6 page 2 Inspecting the solenoid valves and shift elements while driving Edition 07.00
S00.5318.00.20
01-7 Electrical Test

♦ Hand multimeter (e.g. -V.A.G 1526 C-)
♦ Measuring tool set-V.A.G 1594 C-
♦ Adapter cable -V.A.G 1598/18-A-

♦ Binder ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations Fabia 2000 ³
Test requirements
• Battery voltage at least 11.5 volts

• Fuses according to current flow diagram O.K.
• Earth connections O.K.
Test procedure
The automatic gearbox control unit -J217- -arrow- is lo-
cated on the battery tray.
S01-0111
– Switch off ignition, unlock multi-pin connector and re-
move from automatic gearbox control unit -J217-.
– Plug adapter cable -V.A.G 1598/18-A- into the multi- 2
pin connector -arrow 1- and lock in -direction of arrow V.A.G
2-. 1598/18
The adapter cable -V.A.G 1598/18-A- allows to check the
wiring according to the Current Flow Diagram.
– Set the correct measuring range on the measuring

tool before connecting the measuring cables. Other-
wise the electronic components may be destroyed! 1
♦ The indicated nominal values apply for an ambient
temperature of 0 °C to 40 °C.
♦ If the measured values deviate from the nominal val-
ues, determine fault according to Current Flow Dia-
gram. N37-0139
♦ If the measured values only differ slightly from the

nominal values, clean the bushes and plugs of the test
devices and measuring cables and repeat test. Before
replacing the relevant components check their wiring
and connections. Specifically for nominal values be-
low 10 Ω repeat resistance measurement on compo-
nent.
Edition 04.05 Electrical Test 01-7 page 1

S00.5318.02.20
Multi-pin connector of the automatic gearbox control unit -J217- (bushes on -V.A.G 1598/18-)
1 - Earth (terminal 31) 35 - Vehicle speed sender -G68-

2 - not assigned 36 - Vehicle speed sender -G68-
3 - not assigned 37 - not assigned
5 - K cable of diagnosis 39 - not assigned
6 - not assigned 40 - Multi-function switch -F125- (position „R“)
7 - not assigned 41 - Multi-function switch -F125- (position „N“)
8 - not assigned 42 - Multi-function switch -F125- (position „P“)
9 - Gearbox speed sender -G38- 43 - Multi-function switch -F125- (position „3“)
10 - Gearbox speed sender -G38- 44 - Multi-function switch -F125- (position „D“)
11 - not assigned 45 - Power supply (terminal 15)
14 - not assigned 48 - Solenoid valve 1 -N88-
15 - Data BUS high 49 - Solenoid valve 2 -N89-
16 - Data BUS low 50 - Solenoid valve 3 -N90-
18 - Multi-function switch -F125- (position „1“) 52 - not assigned
19 - Multi-function switch -F125- (position „2“) 53 - not assigned
22 - Power supply (terminal 30) 56 - not assigned
25 - Solenoid valve 6 -N93- 59 - not assigned
26 - Solenoid valve 4 -N91- 60 - not assigned
30 - not assigned 64 - Earth return (for valve diagnosis)
32 - not assigned 66 - Power supply for solenoid valve 5 -N92-
33 - Gearbox oil temperature sender (ATF) -G93- 67 - not assigned
34 - Gearbox oil temperature sender (ATF) -G93- 68 - Terminal 15 outlet for multi-function switch
-F125-
Overview of test steps

♦ Only perform the test steps listed per component in
the fault table and the measured value block.
01-7 page 2 Electrical Test Edition 04.05

S00.5318.02.20
Tested component Test step Tested component Test step

Power supply for automatic – Perform test step 1 Solenoid valve 3 -N90- – Perform test step 7
gearbox control unit -J217-
– Perform test step 2
Multi-function switch -F125- Solenoid valve 4 -N91- – Perform test step 8
Vehicle speed sender -G68- – Perform test step 3 Solenoid valve 5 -N92- – Perform test step 9
Gearbox speed sender – Perform test step 4 Solenoid valve 6 -N93- – Perform test step 10
-G38-
Solenoid valve 1 -N88- – Perform test step 5 Gearbox oil temperature – Perform test step 11
sender -G93-
Solenoid valve 2 -N89- – Perform test step 6
Test table
Switch on measuring range: Voltage measurement (20V=)

Test Adapter cable Test covers • Test conditions Specifica- Measures for deviations
step -V.A.G 1598/ tion from nominal value
18- bushes – additional
works
1 22 + 1 Supply voltage for the • Ignition off approx. bat- – Test cable from contact
automatic gearbox tery voltage 1 to earth ⇒ Current
control unit -J217- Flow Diagrams, Electri-
(terminal 30) cal Fault Finding and
Fitting Locations.
– Test cable from contact
22 to terminal 30
⇒ Current Flow Dia-
grams, Electrical Fault
Finding and Fitting Lo-
cations.
– Check battery
⇒ Electrical System;
Rep. Gr. 27.
45 + 1 Supply voltage for the • Ignition off approx. bat- – Test cable from contact
automatic gearbox tery voltage 1 to earth ⇒ Current
control unit -J217- Flow Diagrams, Electri-
(terminal 15) cal Fault Finding and
Fitting Locations.
– Test cable from contact
45 to terminal 15
⇒ Current Flow Dia-
grams, Electrical Fault
Finding and Fitting Lo-
cations.
– Check battery
⇒ Electrical System;
Rep. Gr. 27.

S00.5318.02.20
Switch on measuring range: Voltage measurement (20V=)

works
2 68 + 1 Multi-function switch • Ignition on approx. bat- – Check plug connection
-F125- tery voltage on multi-function switch
42 + 1 Multi-function switch • Selector lever approx. bat- for contact corrosion if
-F125- position „P“ tery voltage necessary replace.
• Selector lever 0- 1 V – Adjusting multi-function

switch ⇒ Chap. 37-4.
position „R“, „N“,
„ D“, „3“, „2“, „1“ – Check wiring from auto-
matic gearbox control
40 + 1 Multi-function switch • Selector lever approx. bat-
-F125- tery voltage unit -J217- to the multi-
position „R“
function switch -F125-
• Selector lever 0-1V ⇒ 01-7 page 6.
position „P“, „N“, – Replacing multi-func-
„ D“, „3“, „2“, „1“ tion switch -F125-
41 + 1 Multi-function switch • Selector lever approx. bat- ⇒ Chap. 37-4.
-F125- position „N“ tery voltage
• Selector lever 0-1V
position „P“, „R“,
„ D“, „3“, „2“, „1“
-F125- position „D“ tery voltage
„N“, „3“, „2“, „1“
-F125- position „3“ tery voltage
„N“, „D“, „2“, „1“
„N“, „D“, „3“, „1“
„N“, „D“, „3“, „2“

S00.5318.02.20
Switch on measuring range: Resistance measurement (20 kΩ)

works
3 35 + 36 Vehicle speed sender min. 0.4 k Ω – Check wiring from auto-
-G68- max. 0.6 k Ω matic gearbox control
unit -J217- to the vehi-
cle speed sender -G68-
prüfen ⇒ 01-7 page 6.
– Replacing vehicle
speed sender -G68-
⇒ Chap. 01-2.
4 9 + 10 Gearbox speed send- min. 0.4 k Ω – Check wiring from auto-
er -G38- max. 0.6 k Ω matic gearbox control
unit -J217- to the gear-
box speed sender -G38-
check ⇒ 01-7 page 6.
– Replacing gearbox
speed sender -G38-
⇒ Chap. 01-2.
Switch on measuring range: Resistance measurement (200 Ω)

works
5 48 + 1 Solenoid valve 1 • Ignition off 9…24 Ω – Check wiring from auto-
-N88- matic gearbox control
6 49 + 1 Solenoid valve 2 • Ignition off 9…24 Ω unit -J217- to the sole-
-N89- noid valve ⇒ 01-7
page 6.
7 50 + 1 Solenoid valve 3 • Ignition off 9…24 Ω
-N90- – Replacing solenoid
valve ⇒ Chap. 38-8.
-N91-
-N92-

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Switch on measuring range: Resistance measurement (20 kΩ)

works
10 25 + 1 Solenoid valve 6 • Ignition off 9…24 Ω – Check wiring from auto-
-N93- matic gearbox control
unit -J217- to the sole-
noid valve ⇒ 01-7
page 6.
– Replacing solenoid
valve ⇒ Chap. 38-8.
11 33 + 34 Gearbox oil tempera- • Ignition off – Check wiring from auto-
ture sender -G93- matic gearbox control
• ATF tempera- unit -J217- to the gear-
ture box oil temperature
approx. 30 °C 2.2 k Ω sender -G93- prüfen
approx. 70 °C 0.5 k Ω ⇒ 01-7 page 6
approx. 110 °C 0.2 k Ω – Replacing gearbox oil

temperature sender
-G93- ⇒ Chap. 01-2.
After the electrical test
– Connect the multi-pin connector -arrow 1- to the pins 2

of the automatic gearbox control unit -J217- and sub-
sequently lock the multi-pin connector -arrow 2-.
Note
When inserting make sure the guides are placed on the
control unit pins.
1
Check the wiring between the automatic

gearbox control unit -J217- and the gear-
box N37-0292

♦ Hand multimeter (e.g. -V.A.G 1526 C-)
♦ Measuring tool set -V.A.G 1594 C-
♦ Adapter cable -V.A.G 1598/18-A-


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Plug connections on gearbox
1- 68-pin plug to automatic gearbox control unit -J217- 2
2- 2-pin plug to vehicle speed sender -G68- 1
3- 2-pin plug to gearbox speed sender -G38-
4- 8-pin plug to the solenoid valves and to the gearbox
3
oil temperature sender -G93-
5 - 10-pin plug to the multi-function switch -F125-
4
– Switch off ignition, unlock multi-pin connector and re-

move from automatic gearbox control unit -J217-.
– Remove battery and battery tray. ⇒ Electrical system; 5 S01-0110
Rep. Gr. 27.
– Plug adapter cable -V.A.G 1598/18-A- into the multi- 2
pin connector -1- and lock in direction of arrow -2-.
V.A.G
1598/18
N37-0139
Inspect wiring to the vehicle speed sender -G68-
– Disconnect the 2-pin plug connection and check the
wiring for interruption.
1 2
S37-0063

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Vehicle speed sender Adapter cable Specification Measures for deviations from nom-
-G68- -V.A.G 1598/18- bushes inal value
1 35 less than 1.5 Ω – Remove line interruption according
2 36 less than 1.5 Ω to Current Flow Diagram
⇒ Current Flow Diagrams, Electri-
cal Fault Finding and Fitting Loca-
tions.
– Check plug for:
♦ Contact corrosion
♦ Water penetration
♦ Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the vehicle speed sender -G68- ⇒ Chap.
01-2.
Inspect wiring to the gearbox speed sender

-G38-
1 2
– Disconnect the 2-pin plug connection and check the
wiring for interruption.
S37-0062

Gearbox speed send- Adapter cable Specification Measures for deviations from nomi-
er -G38- -V.A.G 1598/18- bushes nal value
cal Fault Finding and Fitting Loca-
tions.
– Check plug for:
♦ Contact corrosion
♦ Water penetration
♦ Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the gearbox speed sender -G38- ⇒ Chap.
01-2.

S00.5318.02.20
Inspect wiring to the plug of the solenoid valves
and to the gearbox oil temperature sender -G93-
– Disconnect the 8-pin plug and check the wiring for in- 1 6
terruptions.
7 8
S37-0061

Plug to the solenoid valves Adapter cable Specification Measures for deviations from nom-
and to the gearbox oil tem- -V.A.G 1598/18- inal value
perature sender -G93- bushes
3 26 less than 1.5 Ω cal Fault Finding and Fitting Loca-
4 66 less than 1.5 Ω tions.
5 25 less than 1.5 Ω – Check plug for:
6 33 less than 1.5 Ω ♦ Contact corrosion
7 34 less than 1.5 Ω ♦ Water penetration
8 50 less than 1.5 Ω ♦ Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the gearbox oil temperaturesender
-G93-,the wiring in the slide valve body or the solenoid valves ⇒ Chap. 01-2.
Inspect wiring to the multi-function switch

-F125-
– Disconnect the 10-pin plug and check the wiring for in-
terruptions. 1 6
7 10
S37-0064

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Multi-function switch Adapter cable Specification Measures for deviations from
-F125- -V.A.G 1598/18- bushes nominal value
1 Pins 1 and 2 are not connected to the automatic
2 gearbox control unit -J217-. – Remove line interruption accord-
3 68 less than 1.5 Ω ing to Current Flow Diagram
⇒ Current Flow Diagrams, Elec-
4 42 less than 1.5 Ω trical Fault Finding and Fitting
5 40 less than 1.5 Ω Locations.
6 41 less than 1.5 Ω – Check plug for:
7 44 less than 1.5 Ω ♦ Contact corrosion
8 43 less than 1.5 Ω ♦ Water penetration
9 19 less than 1.5 Ω ♦ Leakage
10 18 less than 1.5 Ω
Note
If this test of the wiring does not show any unauthorised deviations, replace the multi-function switch -F125- ⇒ Chap.
01-2.

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32 – Torque Converter
32-1 Torque Converter
Identification of the torque converter

There are different torque converters. Identification oc-
curs with identification characters -arrow-.
Assignment torque converter/gearbox ⇒ Chap. 00-1.
S32-0006
Torque converter identification characters

(Gearbox installed)
– Remove cover plate -arrow-.
S32-0007
Draining the torque converter
The torque converter must be drained if the ATF is soiled
by metal swarf or if the gearbox is submitted to a major
overhaul.
Removing and installing gasket ring for

torque converter
♦ Drive bushing -T30024-
♦ Ejection lever -MP 3-418-
N32-0024
Edition 07.00 Torque Converter 32-1 page 1

S00.5318.00.20
Removing gasket ring for torque converter
MP 3-418
S32-0008
Insert the gasket ring for torque converter until flush
Installing the torque converter

If ATF is added, only use ATF with spare part number T30024
-G 052 990 A2-.
– Fill converter with 1.5 ltr. of ATF.

– Install converter.
S32-0009
The ATF pump is driven by the torque converter -arrows-.

When installing the torque converter make sure this drive
catches in the recesses of the inner gear of the ATF
pump.
N32-0010
32-1 page 2 Torque Converter Edition 07.00

S00.5318.00.20
The converter is correctly installed if the dimension be-
tween the screw-on flange of the gearbox housing and
the contact surface guide studs of the converter is of 18
mm.
N32-0030
Edition 07.00 Torque Converter 32-1 page 3

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32-1 page 4 Torque Converter Edition 07.00

S00.5318.00.20
37 – Control, housing
37-1 Checking shifting points

Before checking the shifting points
– Perform self-diagnosis and eliminate any faults.

– if necessary initiate basic setting.
– Checking ATF level ⇒ Chap. 37-8.
– Inspecting engine adjustment ⇒ Workshop Manual of
the relevant engine.
Gearbox shifts too soon or too late to the next gear
When inspecting the shifting points take into account that
the speedometer may deviate from the nominal value
within the authorised tolerance.
To inspect the shifting points connect -V.A.G 1552-
⇒ Chap. 01-3.
H = Hydraulic shift (with converter slip)
M = Mechanical shift (without converter slip)
Position of the shift elements in the individual gears
⇒ Chap. 01-6.
Only the kick-down shifting points are indicated.
Shifting points in km/h
Gearbox identification charac- Gearshifts Kickdown

ters Automatic Gearbox 001 km/h1)
ESK 1H-2H 36…42
2H-3H 75…81
3H-3M 75…81
3M-4H 122…128
4H-4M 122…128
1) While driving: The assistance of a second mechanic is required to read off the nominal values.
Edition 07.00 Checking shifting points 37-1 page 1

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37-1 page 2 Checking shifting points Edition 07.00

S00.5318.00.20
37-2 Measure limit speed of the

hydraulic converter
Note
♦ The limit speed of the hydraulic converter is the en-
gine speed on the braked vehicle with the selector le-
ver in position „D“.
♦ The limit speed drops as the altitude above sea level
increases (approx. 125 rpm per 1000 m).

♦ Vehicle system tester -V.A.S 5051 A,B,C -
♦ Vehicle system tester -V.A.S 5052 -
Test sequence
– Connect vehicle system tester -V.A.G oder V.A.S-.

Leave the engine on and select the gearbox control
unit with „Address word“ 02 ⇒ Chap. 01-3.
– Select function 08 „read measured value block“ and
display group number 001.
– Securely lock the vehicle with the hand and foot
brake.
– Place selector lever in selector lever position „D“
– Briefly apply full throttle (max. 5 s), if necessary repeat
test after 20 s. While doing so the speed listed in the
table must be reached.
– If the final speed is not reached, the following faults
may be present:
Speed too high: Forward clutch slips, over-

running clutch slips
Speed too low by up to Check engine setting
200 rpm:
Speed too low by above Torque converter defec-
200 rpm: tive
In case of doubt always first check the engine setting and

if necessary correct.
The correct torque converter must always be assigned to
the gearbox.
Limit speed of the hydraulic converter
Gearbox identification charac- Torque converter identification char- Limit speed of the hydraulic con-
ters Automatic Gearbox 001 acters verter
rpm
ESK ACN 2320…2620
Edition 04.05 Measure limit speed of the hydraulic converter 37-2 page 1
S00.5318.02.20
37-2 page 2 Measure limit speed of the hydraulic converter Edition 04.05
S00.5318.02.20
37-3 Fault finding

This fault finding table lists faults and their possible caus-
es.
Before fault finding

Perform the following tasks before fault finding:
1 - Perform self-diagnosis, this includes:

• Compare control unit identification
• Interrogating fault memory
• Reading measured value block
• eliminating electric/electronic faults
2 - Always check the ATF level

⇒ Chap. 37-8
The gearbox function is impaired if the ATF filling level is
too high or too low.
3 - In the event of complaints about the traction

force and shifting comfort of the gearbox: Meas-
uring the fixed brake speed
⇒ Chap. 37-2
Please note that these measurements will cause the ATF
temperature to rise sharply, therefore always check the
ATF level beforehand (!).
4 - Check whether the vehicle engine or other ve-

hicle systems work perfectly, as disturbances to
these systems may also influence the automatic
gearbox.
If the automatic gearbox does not shift smoothly once
these tasks have been carried out, proceed with fault
finding according to this fault program.
Safety measures
Note
Comply with the safety instructions for test drives
⇒ Chap. 01-1.
Inspecting the shift elements (clutch/brake)

while driving (complaint No. 26 through 36 in
this fault finding procedure)
In the event of problems related to the drive the „solenoid
valves and position of the shift elements“ table indicates
Edition 07.00 Fault finding 37-3 page 1

S00.5318.00.20
what shift elements are activated in the individual gears.

This allows to determine which shift elements do not work
correctly.
To accurately determine the defective shift element drive
and shift through each gear with the vehicle system tester
connected. To this end shift the selector lever from posi-
tion „1“ to „D“ ⇒ Chap. 01-5.
Before disassembling the gearbox and replacing the
clutch or brake, always check the wiring to the electronic
components of the relevant shift elements according to
the Current Flow Diagram. Pay special attention to plug
connections on the gearbox and control unit. Faults in the
vehicle wiring that are not eliminated may result in wrong
diagnoses and hence result in incorrect repairs. The so-
lenoid valves on the slide valve body can also be checked
while driving ⇒ Chap. 01-5.
If the plates of a shift element are burnt always disassem-
ble and clean the gearbox (dirt in ATF). Replace slide
valve body.
Fault finding table
No. Complaint Possible cause of fault Rectifying fault

1 Vehicle does not move Multi-function switch -F125- defec- – Analysing measured value block 004
forwards or backwards tive ⇒ Chap. 01-5
• Contact in switch damaged – Inspecting multi-function switch
-F125-.
• Wiring/plug connection to switch
damaged/not connected accord- – Performing electrical test, test step 2
ing to the Current Flow Diagram ⇒ Chap. 01-7.
• Wiring and insulation defective – Replace wiring and plug connections
⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
Plug in slide valve body broken – Replacing slide valve body ⇒ Chap.
37-10.
Selector lever control cable loose at – Replace shaft retainer
one of its supports:
Shaft retainer (circlip) defective/not
or
clipped
– Replacing and adjusting selector lever

control cable ⇒ Chap. 37-5.
The driver panel is torn because the – Replace the engine/gearbox dowel
dowel sleeves in the engine/gear- sleeves and driver panel.
box flange are missing
2 Vehicle does not move 1. 1st through 3rd gear clutch -K1- – 1. Repair 1st through 3rd gear clutch -
forwards defective K1- ⇒ Chap. 38-3.
3 Vehicle does not reverse Reverse gear-brake -B1- defective – Repairing reverse gear-brake -B1-
⇒ Chap. 38-6.
Reverse gear clutch -K2- defective – Repairing reverse gear-clutch -K2-
⇒ Chap. 38-4.
37-3 page 2 Fault finding Edition 07.00

S00.5318.00.20

4 Gearbox oily Seals or components outside gear- – Clean the engine/gearbox and locate
box leak where the gearbox or engine leaks if
Gearbox leaking necessary use leak-oil search spray
spare part No. G 001 900 A1.
– Seal or replace defective components
on a leaking gearbox.
– Replace gasket rings, gaskets,
screwed connections or gearbox
housing (converter housing).
Engine leaks – Seal engine
ATF level too high, ATF expelled by – Clean gearbox, check ATF level if nec-
fresh air system essary drain off ⇒ Chap. 37-8.
5 ATF escapes around the Distance dimension of the driver – Adjust the distance dimension of the
torque converter panel N.O.K. driver panel ⇒ Engine Mechanics;
Rep. Gr. 13.
Gasket ring for torque converter de- – Replacing the gasket ring for torque
fective converter; if the contact surface on the
Bush in torque converter defective/ torque converter is damaged also re-
loose place the torque converter ⇒ Chap.
32-1.
ATF pump leaks – Disassemble and assemble ATF
pump and replace defective compo-
nents ⇒ Chap. 38-1.
– Inspect converter for damage (visual
inspection).
6 Visible soiling of the ATF ATF-radiator defective, this causes • Precondition: no engine oil in the cool-
and/or engine coolant the coolant and ATF level to drop ant (cylinder head seal etc. O.K.)
– Replace ATF-radiator
– Replace the coolant and ATF.
The coolant may damage plates and
seals in the gearbox. After replacing the
coolant and the ATF:
– Perform a test drive and inspect the

„solenoid valve and position of the
shift elements“ ⇒ Chap. 01-5.
– Inspect shifting points ⇒ Chap. 37-1.
– Measure fixed brake speed ⇒ Chap.
37-2.
If there are functional problems repair the
gearbox ⇒ Chap. 37-9.
7 Gearshift mechanism is Gearshift mechanism is stiff outside – Remove selector lever control cable
stiff the gearbox from the lever/gearshift shaft.
– Repairing the gearshift mechanism
⇒ Chap. 37-4.
– Always replace a buckled selector le-
ver control cable ⇒ Chap. 37-5.
Gearshift mechanism in gearbox – Disassembling and assembling park-
stiff ing position ⇒ Chap. 38-9.

S00.5318.00.20

8 Not all selector lever posi- Selector lever control cable loose at – Replace shaft retainer
tions can be engaged, en- its support:
gaged driving positions Shaft retainer (circlip) defective/not
are not operational or
clipped
– Replacing and adjusting selector lever

control cable ⇒ Chap. 37-5.
9 Parking position does not Selector lever control cable defec- – Replacing and adjusting selector lever
catch tive or incorrectly set control cable ⇒ Chap. 37-5.
Selector lever control cable loose at – Replace shaft retainer
its support:
Shaft retainer (circlip) defective/not
or
clipped
– Replacing selector lever control cable

⇒ Chap. 37-5.
Locking lever, parking gear or lock- – Repairing locking lever, parking gear
ing lever activation defective or locking lever activation ⇒ Chap.
38-9.
10 Parking position „jerks“ Ferraria effect of the locking lever – Apply handbrake before engaging
out of catch (selector lever for parking gear if: parking position.
occasionaly stiff from „P“ Vehicle parked on a hill or the park-
to „R“) ing position catch is put under ten-
sion because of repeated
gearshifting.
11 Noises in the final drive Tapered-roller bearing loud – Replacing tapered-roller bearing
⇒ Chap. 39-2.
Input shaft loud – Replacing input shaft ⇒ Chap. 39-2.
Drive gear loud – Replacing drive gear with output gear
Output gear loud ⇒ Chap. 39-2.
Drive train (input shaft with differen- – Replacing input shaft ⇒ Chap. 39-2.
tial ring gear) loud
12 Driveability: jerking during Throttle valve supports leak – Inspect throttle valve supports and air
idling or jerking during cer- deflector for tightness ⇒ Engine, Fuel
tain engine/gearbox mo- Injection; Rep. Gr. 24.
tions
13 Engine speed drops when Parking/Neutral (P/N) signal is not – Testing data BUS ⇒ Electrical system;
a driving position is en- recognised by the engine control Rep. Gr. 90.
gaged unit
4AV control unit defective – Perform self-diagnosis of the engine
control unit ⇒ Engine, Fuel Injection;
Rep. Gr. 01.

S00.5318.00.20

14 Vehicle does not start or Wiring of the multi-function switch – Check wiring according to current flow
also starts in „R-D-3-2-1“ -F125- or of the starter inhibitor re- diagram ⇒ Current Flow Diagrams,
lay -J207- defective Electrical Fault Finding and Fitting Lo-
cations.
– Testing data BUS ⇒ Electrical Sys-
tem; Rep. Gr. 90.
Vehicle voltage control unit -J519- – Inspecting vehicle voltage control unit
defective -J519- ⇒ Electrical System;
Rep. Gr. 90.
Multi-function switch -F125- defec- – Inspect and if necessary replace multi-
tive function switch -F125- ⇒ Chap. 01-7.
Starter inhibitor relay -J207- defec- – Replacing starter inhibitor relay -J207-
tive ⇒ Chap. 01-2.
15 Selector lever can be shift- Selector lever lock solenoid -N110- – Analysing measured value block 004
ed out of „N“ or „P“ without defective ⇒ Chap. 01-5.
pressing the brake.
– Inspecting selector lever lock solenoid
-N110- ⇒ Chap. 01-7.
Vehicle voltage control unit -J519- – Inspecting vehicle voltage control unit
defective -J519- ⇒ Electrical System;
Rep. Gr. 90.
Wiring for selector lever lock sole- – Check wiring according to current flow
noid -N110- interrupted diagram ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Lo-
cations.
no signal from brake light switch -F- – Analysing measured value block 004
⇒ Chap. 01-5.
– Inspecting and if necessary replacing
brake light switch -F- ⇒ Running
Gear; Rep. Gr. 45.
Data BUS defective – Testing data BUS ⇒ Electrical system;
Rep. Gr. 90.
• Read-out on display of – Select control unit from spare part cat-
-V.A.G 1552-: „no fault detect- alogue and replace ⇒ Chap. 01-2.
ed!“
Automatic gearbox control unit
-J217- defective
16 Selector lever cannot be Brake light switch -F- defective/no – Inspecting and if necessary replacing
shifted out of „N“ or „P“ signal brake light switch -F- ⇒ Running
even though the brake is Gear; Rep. Gr. 45..
pressed.
Data BUS defective – Testing data BUS ⇒ Electrical system;
Rep. Gr. 90.

S00.5318.00.20

17 Shifting does not occur (or Plug of the vehicle speed sender – Re-connect plug
only sporadically) -G68- and gearbox speed sender
-G38- interchanged – Perform a test drive
– Perform self-diagnosis ⇒ Chap. 01-3.
Multi-function switch -F125- defec- – Multi-function switch -F125- ⇒ Chap.
tive 01-7.
• Contacts in switch damaged – Check and if necessary repair wiring
according to current flow diagram
• Wiring/plug connection to switch ⇒ Current Flow Diagrams, Electrical
damaged/not connected accord- Fault Finding and Fitting Locations.
ing to the Current Flow Diagram
• Wiring and insulation defective – Replace wiring and plug connections
⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
Plug in slide valve body broken – Replace slide valve body.
Piston slide valve or solenoid valve – Replacing slide valve body, ATF and
in slide valve body stuck ATF strainer ⇒ Chap. 37-8.
– Perform test drive with -V.A.G 1552-
and check whether all solenoid valves
and shift elements are activated while
driving ⇒ Chap. 01-6.
Pulse gear for vehicle speed sender – Replacing drive gear ⇒ Chap. 39-2.
-G68- loose/broken
18 When shifting gears all Plug of the vehicle speed sender – perform self-diagnosis with the engine
gearshifts „stiff/jerky“ -G68- and gearbox speed sender off, erase fault memory, initiate basic
-G38- interchanged. When interro- setting ⇒ Chap. 01-4.
gating the fault memory in this in-
stance the gearbox speed sender – Re-connect plug
-G38- displays „implausible signal“. – Perform a test drive
– Again perform self-diagnosis ⇒ Chap.
01-3.
no signal from gearbox oil tempera- – Analysing measured value block 002
ture sender -G93-/sender defective ⇒ Chap. 01-5.
– Performing electrical test, test step 11
⇒ Chap. 01-7.
– Replace gearbox oil temperature
sender -G93-.
Short-circuit between the valve – Inspecting/replacing valve wires
wires ⇒ Chap. 01-7.
Incorrect control unit fitted/control – Read out control unit identification
unit defective ⇒ Chap. 01-3.
– Select control unit from spare part cat-
alogue, compare and if necessary re-
place ⇒ Chap. 01-2
Piston slide valve in slide valve – Replacing slide valve body ⇒ Chap.
body or solenoid valve defective 38-8

S00.5318.00.20

19 when shifting gears one one shift element (a clutch or a Check in which gearshift the gear is hard:
gearshift is „stiff/jerky“ brake) defective
– Connect vehicle system tester -V.A.G
1552-; read measured value block
⇒ Chap. 01-3
– Perform a test drive. The table „sole-
noid valves and position of the shift el-
ements“ in the Workshop Manual
indicates which shift elements are af-
fected ⇒ Chap. 01-5.
– replacing the affected shift elements
⇒ Chap. 37-9.
20 Gearshifts too „drawn out“ a clutch or a brake is defective Check in which gearshift the faulty gear
occurs:
– Connect vehicle system tester

-V.A.G 1552-; read measured value
block ⇒ Chap. 01-3.
– Perform a test drive. The table „sole-
noid valves and position of the shift el-
ements“ in the Workshop Manual
indicates which shift elements are af-
fected ⇒ Chap. 01-5.
Torque converter defective – Measure fixed brake speed ⇒ Chap.
37-2.
Piston slide valve is slide valve – Replacing slide valve body ⇒ Chap.
body stuck 38-8
21 Stiff gearshift immediately • Read-out on display – Initiating basic setting ⇒ Chap. 01-4
after repairs -V.A.G 1552- „no fault detected“!
• Damage to the wiring excluded
(plug connections !)
Basic setting not initiated

22 Gearbox shifts down at ATF is insufficiently cooled, by shift- – Check why the ATF temperature rises
constant speed without ing down the gearbox performs a unacceptably. Check out additional in-
visible reason safety function. stallations or modifications to the vehi-
cle that are likely to affect the cooling.
Also the subsequent installation of a
trailer coupling device without corre-
sponding modificaton of the fan motor
may result in cooling problems.
Engine speed signal is not detected – Analysing measured value block 001
by the automatic gearbox control ⇒ Chap. 01-5.
unit
– Perform self-diagnosis of the engine
control unit ⇒ Engine, Fuel Injection;
Rep. Gr. 01.
– Testing data BUS ⇒ Electrical system;
Rep. Gr. 90.
23 Gearbox does not shift Accelerator pedal position sender – Inspecting accelerator pedal position
during kickdown -G79- defective/no signal sender -G79- ⇒ Engine, Fuel Injec-
tion; Rep. Gr. 24.
– Initiating basic setting ⇒ Chap. 01-4.
– Testing data BUS ⇒ Electrical system;
Rep. Gr. 90.

S00.5318.00.20

24 Gearbox only shifts as Piston slide valve in slide valve – Replacing slide valve body ⇒ Chap.
heating increases body or solenoid valve defective 38-8.
Given an ATF temperature below
15° C the gearbox does not shift
into 4th gear. No fault.
25 Gearbox shifts into emer- Read-out on display of -V.A.G 1552- – perform self-diagnosis with the engine
gency running mode gearbox speed sender -G38- „im- off, erase fault memory, initiate basic
plausible signal“ plug connection of setting ⇒ Chap. 01-4.
the gearbox speed sender -G38-
and vehicle speed sender -G68- in- – Re-connect plug
terchanged – Perform a test drive
– Perform self-diagnosis again
Plug connection at gearbox dam- – Inspect wiring and plug connections
aged/loose contact according to the Current Flow Dia-
gram and repair if necessary
• Soiling or corrosion of contacts ⇒ Current Flow Diagrams, Electrical
• Plug contacts in plug housing Fault Finding and Fitting Locations.
damaged (not fully inserted)
• Short-circuit/interruption in wiring
loom
Short-circuit/interruption between – Perform self-diagnosis and electrical
the valve wires or wires to the sole- test, subsequently replace wiring or
noid valves components ⇒ Chap. 01-3.
Plug in slide valve body broken – Replacing slide valve body ⇒ Chap.
38-8.
Piston slide valve is slide valve – Replacing input shaft ⇒ Chap. 38-8.
body stuck
• Read-out on display of – Read out control unit identification
-V.A.G 1552-: „no fault detect- ⇒ Chap. 01-3.
ed!“
– Select control unit from spare part cat-
Incorrect control unit fitted/control alogue and replace if necessary
unit defective
26 Selector lever position „1“ 1. 1st through 3rd gear-clutch -K1- – Observe the safety measures and
automatic gearbox does or reverse gear-brake -B1- defec- notes: „Inspecting the solenoid valves
not shift into 1st gear (no tive and shift elements while driving“
power transmission in 1st ⇒ Chap. 01-6.
gear)
– Repairing reverse gear-brake -B1-
⇒ Chap. 38-6.
– 1. Repairing 1st through 3rd gear-
clutch -K1- ⇒ Chap. 38-3.
– Repairing the overrunning clutch
⇒ Chap. 38-2.
27 Selector lever position „D, 1. 1st through 3rd gear clutch -K1- – Observe the safety measures and
3 or 2“ automatic gearbox or overrunning clutch defective notes: „Inspecting the solenoid valves
does not shift into 1st gear and shift elements while driving“
(no power transmission) ⇒ Chap. 01-6.
– 1. Repairing 1st through 3rd gear-
⇒ Chap. 38-2.

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28 Selector lever position „D, 2. 2nd and 4th gear-brake -B2- de- – Observe the safety measures and
3 or 2“ automatic gearbox fective notes: „Inspecting the solenoid valves
does not shift into 2nd and shift elements while driving“
gear ⇒ Chap. 01-5.
– 2. Repairing 2nd through 4th gear-
brake -B2- ⇒ Chap. 38-7.
⇒ Chap. 38-2.
29 Selector lever position „D 3. 3rd and 4th gear-clutch -K3- de- – Observe the safety measures and
or 3“ automatic gearbox fective notes: „Inspecting the solenoid valves
does not shift hydraulically and shift elements while driving“
into 3rd gear (3H) ⇒ Chap. 01-5.
– 3. Repairing 3rd through 4th gear-
30 Selector lever position „D Lockup clutch defective – Observe the safety measures and
or 3“ automatic gearbox notes: „Inspecting the solenoid valves
does not shift mechanical- and shift elements while driving“
ly into 3rd gear (3M) ⇒ Chap. 01-5.
– Replacing torque converter ⇒ Chap.
32-1.
31 Selector lever position „D“ Lockup clutch defective – Observe the safety measures and
automatic gearbox does notes: „Inspecting the solenoid valves
not shift mechanically into and shift elements while driving“
4th gear (4M) ⇒ Chap. 01-5.
– Replacing torque converter ⇒ Chap.
32-1.
32 Selector lever position „R“ Reverse gear-clutch -K2- defective – Observe the safety measures and
automatic gearbox does reverse gear-brake -B1- defective notes: „Inspecting the solenoid valves
not shift into reverse gear and shift elements while driving“
⇒ Chap. 01-5.
– Repairing reverse gear-clutch -K2-
⇒ Chap. 38-4
– Repairing reverse gear-brake -B1-
⇒ Chap. 38-6.

S00.5318.00.20

S00.5318.00.20
37-4 Inspecting gearshift

mechanism
Inspecting gearshift mechanism
Note
♦ In selector lever positions „1“, „2“, „3“, „D“ and „R“ it
must not be possible to activate the starter.
♦ At speeds above 5 km/h and shifting in selector lever
position „N“ the selector lever lock solenoid must not
engage and block the selector lever. Selector lever
can be shifted in a driving position.
♦ At speeds below 5 km/h (virtual standstill) and shifting
in selector lever position „N“ the selector lever lock so-
lenoid must only engage after approx. 1 s. The selec-
tor lever can only be moved from position „N“ by
activating the brake pedal.
Selector lever in position „P“ or „N“ and ignition

switched on:
• Brake pedal is not actuated:
The selector lever is locked and cannot be shifted
from position „P“ or from „N“. The selector lever lock
solenoid blocks the selector lever.
• Brake pedal is actuated:

The selector lever lock solenoid releases the selector
lever. It is possible to engage a driving position. Slow-
ly shift selector lever from „P“ through „R, N, D, 3, 2,
1“; while doing so check whether the selector lever po-
sition in the dash panel insert corresponds with the ac-
tual selector lever position.
Inspecting and adjusting the selector le-

ver control cable
Inspection
– Shift selector lever to position „P“.
– Remove noise insulation ⇒ 1.4/55, 1.4/74 Engine -
Mechanics; Rep. Gr. 10.
– Lever off upwards selector lever control cable -A- from
lever/gearshift shaft -B- with open-end wrench and lay
aside in such a way that the extremity can move free- A
ly.
1 - Open-end wrench size 13, commercially available
Do not bend or buckle selector lever control cable. B
– Shift selector lever from „P“ to „1“. 1
S37-0103
Edition 07.00 Inspecting gearshift mechanism 37-4 page 1

S00.5318.00.20
• Gearshift mechanism and selector lever control cable

must move smoothly when shifting gears, if necessary
replace selector lever control cable ⇒ Chap. 37-5 or
repair gearshift mechanism.
– Check front boot on the selector lever cable control for

damage, if necessary replace control cable.
– Use pliers to press selector lever control cable onto
the lever/gearshift shaft.
Setting
– Release screw -A- at the front ball socket of the selec-
tor lever control cable -B-.
– Place lever/gearshift shaft at gearbox in „P“. Locking A
lever must engage in parking gear, both front wheels
are blocked (cannot be simultaneously turned in one
direction).
– Tighten screw -A- (8 Nm). B
– Inspect gearshift mechanism ⇒ 37-4 page 1.
S37-0105
37-4 page 2 Inspecting gearshift mechanism Edition 07.00

S00.5318.00.20
37-5 Removing and Installing

Shift Mechanism
Removing and Installing Shift Mecha-

nism
Note
After installing, check gearshift mechanism ⇒ Chap. 37-
4.
Removing
P
D
R
1
2
3
– First check whether a coded radio set has been in-
stalled. If this is the case obtain the anti-theft code.
– Disconnect the earth strap from the battery with the ig-
nition off.
– Remove grip of selector lever ⇒ 37-5 page 5.
– Removing the centre console ⇒ Body Work;
Rep. Gr. 68. S37-0104
– Remove surround -arrows- with cover and selector le-
ver position indicator by pulling it upwards from the
gearshift mechanism.
– Disconnect the plug connection -arrow- of the selector
lever position indicator.
S37-0107
– Disconnect the plug connector -arrow- for selector le-

ver lock solenoid -N110-.
S37-0108
Edition 07.00 Removing and Installing Shift Mechanism 37-5 page 1

S00.5318.00.20
– Detach bracket -1- below the exhaust system.

– Unclip the Lambda probe line from holder -2-.
– Remove protective cover -3- and disconnect the plug
connection.
– Separate exhaust system at the double clamp -4-.
– Remove exhaust pipe with catalyst ⇒ 1.4/55, 1.4/74
Engine - Mechanics; Rep. Gr. 26.
– Unbolt bracket -5- for exhaust system.
– Remove heat shield -6-.
– Unscrew cover at bottom from the shift housing.

– Use a screwdriver to press off the selector lever con-
trol cable -3- from the selector lever -2-.
1
– Remove the retaining clip -1- for the selector lever
control cable.
2 3
A37-0213
37-5 page 2 Removing and Installing Shift Mechanism Edition 07.00

S00.5318.00.20
– Unscrew nuts -arrows- attaching the shift housing.
While doing do not allow the shift housing to fall.
– Pull shift housing from selector lever control cable and

lower.
2
3
D
N
R
P
Installing
– The installation occurs in reverse order.
– When installing replace the seal between the selector
lever control cable and the shift housing and the seal
between the cover and the shift housing.
Tightening torques: S37-0106
Shift housing to body 25 Nm

Strut to body 25 Nm
Removing and installing the selector le- 1

ver control cable
Note
♦ Adjusting the selector lever control cable ⇒ Chap. 37-
4.
♦ Inspecting the gearshift mechanism ⇒ Chap. 37-4.
2
Removing
S37-0109
– Pull off the retaining clip -1- for the selector lever con-
trol cable at the support -2-.
– Unhook selector lever control cable from the holders
-arrows-.
S37--0110

S00.5318.00.20
– Lever off selector lever control cable -A- from the le-
ver/gearshift shaft -B- using open-end wrench.
A
B
1
S37-0103
– Detach bracket -1- below the exhaust system.

– Unclip the Lambda probe line from holder -2-.
– Remove protective cover -3- and disconnect the plug
connection.
– Separate exhaust system at the double clamp -4-.
– Unbolt bracket -5- for exhaust system.
– Remove heat shield -6-.
– Unscrew cover at bottom of gearshift mechanism.

S00.5318.00.20
– Use a screwdriver to press off the selector lever con-
trol cable -3- from the selector lever -2-.
1
– Remove the retaining clip -1- for the selector lever
control cable.
– Remove selector lever control cable.
– Carefully pull the selector lever control cable out of the
engine compartment.
Installing
– The installation occurs in reverse order.
Note
♦ Inspect boot for damage; the boot must be replaced
together with the selector lever control cable.
♦ Check correct fitting of the boot and do not install the
boot twisted.
♦ Do not bend or buckle selector lever control cable. 2 3
• Selector lever and lever/gearshift shaft are in position
„P“, the front wheels are blocked.
A37-0213
– When installing replace the seal between the selector
lever control cable and the shift housing and the seal
between the cover and the shift housing. D
3
Removing and installing the selector le- 2
ver grip
1
1
Removing
– Shift selector lever to position „2“.
2
– Push sleeve -1- down.
– Pull off grip -2- from selector lever.
S37-0111
Installing
– Push the grip -2- onto the selector lever up to the stop. D
3
Fitting position:
Button points towards driver.
2 1
1
– Slide the sleeve -1- upwards while turning until the two B
wide pegs of the grip -A- catch in the slots of sleeve
-B- and the sleeve and grip are felt to click in position. A
– Shift selector lever to position „P“. 2
S37-0112

S00.5318.00.20

S00.5318.00.20
37-6 Disassembling and assembling the gearshift mechanism
Note
Grease bearing and friction surfaces with polycarbamide grease -G 052 142 A2- SP No.
1 - Grip for selector lever

T removing and installing
⇒ Chap. 37-5
1
2 - Sleeve
27 2
T catches in the selector lever 13
28
grip 14 3
T blocks the pulling off of the 29
selector lever grip
15
3 - Cover 30 4
T with selection range 31
4 - Cover strip 16
T insert in surround ⇒ item 7
5 - Selector lever position indica- 6
tor 32 17
T Clip printed circuit board for 33 5
selector lever position and in- 34 18
6
dicator (lighting) off or on 35
T The contacts for selector le- 36
ver position point towards the 19 7
contact spring ⇒ item 27 of 38 37
the selector lever
20
T Secure plug housing with 8
holder ⇒ item 6 to surround 9
⇒ item 7 39
21
T Hook fiberoptic cable and ca-
ble to plug housing onto its 22
10
supports on the surround. 23
T Disconnect and connect plug 40 41 11
connection ⇒ 37-6 page 3 24
12
6 - Bracket 25
T for wiring loom
7 - Surround
42 26 S37-0100
T to remove pull off upwards
with selector lever position indicator ⇒ item 5 and cover ⇒ item 3
8 - 7 Nm
9 - Washer
10 - Locking segment
11 - Bracket
12 - Latch spring with roller
T catches in the slots of the selector lever ⇒ item 13
T adjust ⇒ 37-6 page 3
13 - Selector lever
T with tension rod, pressure spring, slots, contact spring for selector lever position and release for interlock ca-
ble
T removing and installing ⇒ Chap. 37-5
14 - Roller
15 - Circlip
16 - Gasket
T with studs press into the supports of the gearshift bracket ⇒ item 17
Edition 07.00 Disassembling and assembling the gearshift mechanism 37-6 page 1
S00.5318.00.20
17 - Gearshift bracket
T need not be removed to replace the selector lever control cable or the component parts of the gearshift mech-
anism
18 - Collar screw
T with serration
T only counterhold screw head, do not turn!
T grease at shank
19 - Locking lever
T to lock in selector lever position „P“
20 - Washer
21 - 2.5 Nm
22 - Gasket
T always replace
23 - 8 Nm
T 2 pieces
24 - Bottom cover
T for gearshift bracket
25 - 1.5 Nm
T 14 pieces
26 - Gasket
T always replace
27 - Contact spring
28 - Contact plate
29 - 4 Nm
T to release and tighten put selector lever in „P“
30 - 1.3 Nm
T 2 pieces
T Solenoid on gearshift bracket
31 - Selector lever lock solenoid -N110-
T removing and installing ⇒ 37-6 page 3
T remove and install in selector lever position „1“ only
T Move wiring loom in such a way that it can neither be damaged by the selector lever nor by the selector lever
lock solenoid
T when removing pay attention to the spring and locking bolt
T install together with the locking bolt and spring, while doing so move the selector lever up and down a little
T can be checked in the electrical test and in the measured value block ⇒ Rep. Gr. 01
32 - Pressure spring
33 - Locking bolt
34 - 13 Nm
T always replace
35 - Washer
36 - 25 Nm
T with collar
T 4 pieces
37 - Gasket
T always replace
38 - Retaining clip
T always replace
T for selector lever control cable on gearshift bracket
T install the angled end towards the inside of the gearshift bracket
39 - Selector lever control cable
T do not bend or buckle
T if the boot is damaged the selector lever control cable must be replaced
37-6 page 2 Disassembling and assembling the gearshift mechanism Edition 07.00
S00.5318.00.20
T inspecting and setting ⇒ Chap. 37-4
T do not grease the ball sockets at the cable extremities
40 - 8 Nm
T for selector lever control cable
41 - Retaining clip
T for selector lever control cable on gearbox
T always replace
T angled end point towards the end of the selector lever control cable
42 - 25 Nm
T 2 pieces
T for support to gearbox
Adjusting latch spring with roller
Adjusting requirements:
• Grip for selector lever removed
• Cover of gearshift mechanism removed
• Centre console removed
– Release screw -1 -.
1
– Press latch spring with roller in the direction of the ar-
row in the slots of the selector lever -2-.
While doing so tighten screw -1-.
Removing and installing selector lever

lock solenoid -N110-
Removing
– First check whether a coded radio set has been in-
stalled. If this is the case obtain the anti-theft code. 2 S37-0124
nition off.
– Removing selector lever grip ⇒ Chap. 37-5.
– Removing the centre console ⇒ Body Work;
Rep. Gr. 68.
– Remove surround -arrows- with cover and selector le-
P
D
N
R
1
2
3
ver position indicator by pulling it upwards from the

gearshift mechanism.
S37-0104
S00.5318.00.20
– Disconnect the plug connection -arrow- of the selector

lever position indicator.
S37-0107
– Disconnect the plug connector -1- for selector lever

lock solenoid -N110-.
– Lever off holder of wiring loom -2- from gearshift
bracket.
– Cut through cable straps -3-.
2 1
3 S37-0113
– Remove surround from gearshift bracket -arrows 1-.

The rear screw is not visible in the figure.
1
1
– Release screws -arrows 2- from the solenoid.
2
S37-0114
S00.5318.00.20
– Pull out the solenoid -1-, the spring -2- and the locking
bolt -3-.
Installing 3
The installation occurs in reverse order, while paying at-
tention to the following:
2
• To install the solenoid the selector lever must be in po-
sition „1“.
– Insert the solenoid with spring and locking bolt in the S37-0119
gearshift bracket.
– The locking bolt must catch into the support -arrow- of
the gearshift bracket.
– Slightly move the selector lever while doing so.
S37-0120
After installation the locking bolt -1- must be located at

the front side of the gearshift bracket -2-.
– Inspecting the gearshift mechanism ⇒ Chap. 37-4.
2 S37-0121
S00.5318.00.20
S00.5318.00.20
37-7 Removing and installing

the gearbox
Removing
♦ Gearbox mount -3282-
♦ Adjusting plate -3282/24-
♦ Torque wrench (5...50 Nm), e.g. -V.A.G 1331-
♦ Engine/gearbox jack, e.g. -V.A.G 1383 A-
♦ Gearbox attachment device -MP 3-478-
♦ Hose clamps -MP 7-602-
1
♦ Supporting device -MP 9-200-
– Remove the engine trim panel.

– Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
nition off. 2
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27. S37-0109
– Pull off the retaining clip -1- for the selector lever con-
trol cable at the support -2-.
– Lever off selector lever control cable -A- from the le-
ver/gearshift shaft -B- using open-end wrench.
A
B
1
S37-0103
Edition 07.00 Removing and installing the gearbox 37-7 page 1

S00.5318.00.20
– Clamp off the two ATF-radiator hoses with hose

clamps -MP 7-602- and remove from ATF-radiator.
– Close ATF-radiator with a clean plug.
MP 7-602
S37-0067
– Remove the support for selector lever control cable

-1- from the gearbox -arrows-.
S37-0068
– Disconnect the plug connection -1- from holder -2-.

– Remove holder -2- from the gearbox -arrows-. 1
S37-0069
37-7 page 2 Removing and installing the gearbox Edition 07.00

S00.5318.00.20
– Pull out cable duct -1- from the lifting eye for the gear-
box -2- in the -direction of the arrow-.
S37-0070
– Pull off cable duct -1- from the engine/gearbox con-

necting screw -2- in the -direction of the arrow-.
– Remove engine/gearbox connecting screws at the
top.
1
– Remove securing screw for starter at the top.
S37-0071
– Pull off and disconnect the plug connection -1- from

the bracket -2- on the suspension strut dome in the
-direction of the arrow-.
– Remove front left wheel and raise vehicle. 2 1
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66; Wheelhouse liner.
– Remove left drive shaft ⇒ Running gear; Rep. Gr. 40.
– Remove right drive shaft from the flange shaft and tie
up as far as possible. Avoid damaging the paintwork S37-0072
on the drive shaft during this operation.
– Removing starter ⇒ Electrical System; Rep. Gr. 27.

S00.5318.00.20
– Unplug connector -arrow- from speedometer sender

-G22-.
– Remove converter cover plate.
S37-0074
– Release nut -arrow- from the torque converter (3 piec-

es).
– Unscrew the engine/gearbox connecting screw above
the right flange shaft.
N37-0556
– Unbolt pendulum support -1- -arrow A-.

– Remove cover plate -2- from the gearbox -arrow B-.
– Remove protection plate for ATF-pan. 2
B
B A
1
A
S37-0075
A

S00.5318.00.20
– Install supporting device -MP 9-200-.
Note
When installing the lifting hooks of the supporting device,
pay attention to hose and cable connections in the area
of the lifting eyes of the engine to avoid damaging them.
– Take up the weight of the engine/gearbox unit at the

spindles.
– Unscrew the fixing screws -arrows- from the gearbox
mount.
– Release screws for gearbox mounting bracket.
S37-0076
– Remove screws -2- for engine mounting.

– Lower engine/gearbox unit approx. 60 mm and re- 2
move gearbox mounting bracket.
Note
When lowering the engine/gearbox unit, make sure the
gearbox does not touch the assembly carrier. 1
3
S10-0140

S00.5318.00.20
– Insert engine mount -3282- into engine/gearbox jack,

e.g.-V.A.G 1383 A-.
3282/24
– Align the engine/gearbox jack with gearbox mount
-3282-, adjusting plate -3282/24- for „001“ gearbox
3282
and the support elements (adjusting plate only fits in
one position).
– Align arms of the gearbox mount to match the holes in
the adjusting plate.
– Screw in the mounting elements as shown on adjust-
ing plate.
– Position engine/gearbox jack below vehicle, arrow
symbol on adjusting plate points in the direction of
travel/vehicle.
N37-0559
V.A.G 1383A
– Align adjusting plate parallel to the gearbox and lock
securing mount -arrow- at gearbox.
3282/24 3282
S37-0077
– Unbolt heat shield -1- from the gearbox -arrow A-.

– Release screw for engine/gearbox fixation -arrow B-.
– Push gearbox off engine, simultaneously press off the
torque converter from the driver disc.
– Push torque converter against the ATF-pump.
– Ask a second mechanic to push the engine forwards. A
1
– After this lower gearbox carefully. B
– Secure converter against dropping out.
S37-0073

S00.5318.00.20
– Bolt the gearbox suspension device -MP 3-478- to the
flange of the gearbox housing.
MP 3-478
– Adjust supporting arm at slide with locking pin -arrow-.
Number of visible holes = 5.
– Raise gearbox with workshop crane and gearbox sus-

pension device -MP 3-478-.
– Place down gearbox, e.g. in a transport container.
Installing
The installation of the gearbox occurs in reverse order,
while paying attention to the following:
S37-0122
– Install engine/gearbox mounting free of stress ⇒ 1.4/
55; 1.4/74 Engine, Mechanics; Rep. Gr. 10.
– Check adjustment of the selector lever control cable,
if necessary adjust ⇒ Chap. 37-4.
– Checking ATF level and topping up ⇒ Chap. 37-8.
Note
♦ Check whether the dowel sleeves for centering the
engine/gearbox are present in the cylinder block; in-
sert if necessary.
♦ Installing starter/cable ⇒ Electrical System;
Rep. Gr. 27.
♦ Check the vehicle equipment when the battery is re-
connected. Encode the radio, re-set the clock, initial-
ise the power windows ⇒ Inspection and
Maintenance.
Tightening torques
Gearbox on engine. 7 1
6
Pos. Screw Pieces Nm
1 M12 x 65 2 80 5
2 M12 x 75 1 45 4
3 M7 x 12 2 15
A
4 M12 x 70 1 80
51) M8 x 30 1 25 A
6 M8 x 35 1 25 2
72) M8 x 35 1 25
3 3
1) Screw with threaded pin M8
2) Screw with T-pin S37-0118
A: Dowel sleeves for centering

S00.5318.00.20
Pendulum support
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
Mounting sequence:
– Tighten screws -1- and -2- by hand.

– Ensure maximum distance between gearbox and as- 1
sembly carrier and tighten screws -1- to tightening
torque.
– Then tighten screw -2- to tightening torque.
2 S10-0133
1 - 30 Nm + 90° (1/4 turn) - replace
2 - 40 Nm + 90° (1/4 turn) - replace
Components Torque
Converter to driver disc 85 Nm
Protection plate for ATF-pan to
45 Nm
gearbox
Selector lever control cable sup-
25 Nm
port to gearbox
Left gearbox mounting bracket to
20 Nm + 90°
gearbox M81)
Gearbox mounting bracket to gear-
40 Nm + 90°
box mount M10 1)
Tighten drive shaft to flange shaft
I - 10 Nm
diagonally across in 2 steps (I and
II - 40 Nm
II) to M81)
Plate nut of drive shaft to wheel-
50 Nm
bearing housing
Steering joint to track control arm
20 Nm + 90°
M81)
Coupling rod to anti-roll bar 40 Nm
Wheel bolts to wheel hub 120 Nm
1) Always replace these bolts.

S00.5318.00.20
37-8 Checking and topping up

ATF level
♦ ATF filling system -V.A.G 1924-
If ATF is added, use ATF with Spare Part No.

-G 052 990 A2-.
– The gasket ring -arrow- for the screw plug for ATF in- N38-0037
spection must always be replaced.
Inspecting ATF level

V.A.G 1924
Test conditions
• Gearbox not in emergency running mode, ATF tem-
perature not above 30°C.
• Vehicle on level ground
• Selector lever in „P“
Inspection
– Attach the reservoir of the ATF filling system
-V.A.G 1924- to the vehicle.
– Connect vehicle system tester -V.A.G 1552- with the
diagnostic cable -V.A.G 1551/3- ⇒ Chap. 01-3.
– Enter address word „02 gearbox electronics“ and
move forward until „select function XX“ appears in the
display.
– Start engine.
– Raise vehicle.
V.A.G 1552 S37-0078
– Position the catch pan under the gearbox.
Read-out on display: Vehicle system test HELP

Select function XX
– Press 0 and 8 for the function „reading measured Reading measured value block
value block“ and confirm the entry with Q . Enter display group number XXX
– Press 0 , 0 and 2 for the function „display group
number 002“ and confirm the entry with Q .
Reading measured value block 2 ->
0% 4% 30°C 12.9 V
The third display field indicates the ATF temperature.
Note
At the start of the inspection the ATF temperature must
not exceed 30 °C.
Edition 07.00 Checking and topping up ATF level 37-8 page 1

S00.5318.00.20
– Bring ATF to test temperature.

Test temperature: 35 °C to 45 °C
– Remove screw plug for ATF inspection in the oil pan

-arrow-.
The ATF present in the overflow tube flows out.
If ATF drips out of the hole:
It is not necessary to top up with ATF.
– Tighten screw plug with new gasket ring to 15 Nm.

This completes the ATF inspection.
S37-0079
Topping up ATF
– Lever off cap -arrow- securing the screw plug with a
screwdriver.
This destroys the cap catch, therefore always replace the
cap.
S37-0080
– Pull screw plug from the filler tube.
– Top up ATF with the ATF filling system -V.A.G 1924-
until ATF flows out of the inspection hole -arrow-.
Note
Too much or too little ATF filling impairs the gearbox func-
tion.
V.A.G. 1924
S37-0081
37-8 page 2 Checking and topping up ATF level Edition 07.00

S00.5318.00.20
– Tighten screw plug with new gasket ring -arrow 1- to
15 Nm.
– Insert screw plug of the filler tube and secure with new
cap -arrow 2-.
Replacing ATF
S37-0082
– Remove screw plug for ATF inspection in the oil pan
-arrow-.
– Unscrew the overflow tube through the inspection
hole.
– Drain the ATF.
– Install overflow tube.
– Tighten the screw plug by hand.
If ATF is added, use ATF with Spare Part No.
-G 052 990 A2-.
– Pour in approx. 2 litres of ATF through the filler tube.

– Then start the engine and while the vehicle is standing
shift through all selector lever positions once. S37-0079
– Subsequently check ATF level and top up ⇒ Chap.
37-8.
Edition 07.00 Checking and topping up ATF level 37-8 page 3

S00.5318.00.20
37-8 page 4 Checking and topping up ATF level Edition 07.00

S00.5318.00.20
37-9 Disassembling and assembling the gearbox
Gearbox with shift elements
Arrangement of the shift elements

Before repairing the gearbox first perform self-diagnosis ⇒ Rep. Gr. 01.
1- 3. 3rd and 4th gear-clutch -K3-

2- Reverse gear-brake -B1-
3- Overrunning clutch 1 2 3 4 5 6 7
4- Reverse gear-clutch -K2-
5- 1. 1st through 3rd gear clutch
-K1-
6 - 2. 2nd and 4th gear-brake -B2-
7 - Lockup clutch integrated in
torque converter -LC-
N37-0612
Position of the shift elements

In the event of complaints about unsatisfactory accelera-
tion and speed values or more generally for drive faults,
refer to the following table to determine which shift ele-
ments are activated in the individual gears. This allows to
determine which shift elements do not work correctly.
All gears are hydraulically shifted.
The 3rd and 4th forward gears are mechanically driven by
the torque converter lockup clutch at a specified load and
speed.
Edition 07.00 Disassembling and assembling the gearbox 37-9 page 1

S00.5318.00.20
Gear B1 B2 K1 K2 K3 F LC
R X X
1H (X) X X
2H X X
3H X X
3M X X X
4H X X
4M X X X
X - closed clutches, brakes or overrunning clutch

(X)- -B1- is only used as an engine brake in selector le-
ver position „1“.
H - hydraulic
M - mechanical
Removing and installing ATF radiator and ATF filler tube

1 - Gearbox housing
2 - Sealing ring
T always replace 4
3 - 8 Nm 5
4 - 25 Nm 1 2 3
5 - O-ring 6
T always replace
6 - ATF radiator
7 - O-ring 7
T always replace
8 - O-ring
T always replace
9 - ATF filler tube
10 - 8 Nm
11 - O-ring
T always replace
12 - Plug
13 - Cap
T to secure the screw plug af-
ter checking the ATF level
⇒ Chap. 37-8
T always replace
13
12
11
10 9 8
N37-0602
37-9 page 2 Disassembling and assembling the gearbox Edition 07.00

S00.5318.00.20
37-10 Disassembling and assembling planetary gear - Summary of

components
♦ Disassembling and assembling planetary gear ⇒ Chap. 37-11
♦ Fitting position of the adjusting washer and axial needle bearing in the planetary gear ⇒ 37-10 page 4
I - Removing and installing ATF

pump up to large sun gear l
⇒ 37-10 page 2
II - Removing and installing cov-
er for gearbox housing up to
the drive gear ⇒ 37-10
page 3 II
S37-0084
Edition 07.00 Disassembling and assembling planetary gear - Summary of 37-10 page 1
S00.5318.00.20 components
I - Removing and installing ATF pump up to large sun gear

♦ Overview ⇒ 37-10 page 1
1 - 20 Nm
2 - ATF pump
9 10
T disassembling and assem- 3 4 5 6 7 8
bling ⇒ Chap. 38-1
3 - Gasket
1 2
T for ATF pump
4 - Brake band -B2-
T 2. 2nd and 4th gear-brake
T setting ⇒ Chap. 37-12 16
T lay aside in fitting position
⇒ Chap. 37-11
T insert the piston pressure rod 15
⇒ item 19 and adjusting
screw ⇒ item 19 in the
moulded part of the brake
band
5 - 45 Nm
6 - Adjusting screw
T for brake band -B2-
T always replace
14
T setting brake band ⇒ Chap. 13
37-12 12
7 - Adjusting washer
11
T Determining thickness
⇒ Chap. 37-12, setting
21
clutch clearance between - 20
K2- and ATF pump
8 - Reverse gear-clutch -K2-
19
T disassembling and assem-
bling ⇒ Chap. 38-4 18
9 - Axial needle bearing 17 N37-0614
T check fitting position
⇒ 37-10 page 4
10 - 1. 1st through 3rd gear clutch -K1- with turbine shaft
T disassembling and assembling ⇒ Chap. 38-3
11 - Axial needle bearing
T check fitting position ⇒ 37-10 page 4
12 - Drive shaft
13 - Axial needle bearing with washer
T check fitting position ⇒ 37-10 page 4
14 - Sun gear, large
15 - Drive pinion
T assigned to gearbox identification characters as a spare part
16 - Gearbox housing
17 - Circlip
18 - Cover
T with 4th gear control piston
19 - Control piston 2nd and 4th gear brake
37-10 page 2 Disassembling and assembling planetary gear - Summary of

components
Edition 07.00
S00.5318.00.20
20 - Spring
21 - Spring
II - Removing and installing cover for gearbox housing up to the drive gear
♦ Overview ⇒ 37-10 page 1
1 - 20 Nm
2 - Cover for gearbox housing 16
T with piston and spring sup-
17
port plate for reverse gear-
18
brake -B1- 22
3 - Axial needle bearing
T check fitting position
⇒ 37-10 page 4
4 - Circlip
5 - Disc spring
19
T Check fitting position: large 20
diameters face one another 21
6 - Pressure plate -B1-
8
7 - Outer plate -B1-
T Piece number outer plates - 9
B1- ⇒ Chap. 00-3 10
11
8 - Inner plate -B1- 12
T Piece number inner plates - 13
B1- ⇒ Chap. 00-3 14
15 7
T lay in ATF for 15 minutes be- 14
fore installing
9 - Pressure plate -B1-
10 - 3. 3rd and 4th gear-clutch -K3- 1
11 - Axial needle bearing 8
check fitting position ⇒ 37-10 5 4 3 2
page 4
7 6 S37-0085
12 - Planet carrier
T when inserting in overrun-
ning clutch turn to the left
13 - Circlip
T for overrunning clutch
14 - Thrust washer
T for overrunning clutch ⇒ item 15
15 - Overrunning clutch
16 - Tensioning screw, 60 Nm
T secures the drive gear
17 - Lock washer
T for tensioning screw
T always replace
Edition 07.00 Disassembling and assembling planetary gear - Summary of 37-10 page 3
T insert the 4 pegs of the lock washer in the holes of the gearbox housing
18 - Drive gear with ring gear
T Removing and installing ring gear ⇒ Fig. 1 in 37-10 page 4
19 - Ring gear
20 - Circlip
T for ring gear
T removing and installing ⇒ Fig. 1 in 37-10 page 4
21 - Input gear
T with grooved ball bearing
T Grooved ball bearings cannot be removed from the drive gear
Fig. 1: Removing and installing the ring gear from

the output gear A B
Removing:
– Compress circlip -A- and remove ring gear -B- from

the drive gear -C-.
Installing:
C
– Insert the circlip -A- in the circular slot of the drive
gear.
– Compress the circlip and insert ring gear in the serra-
tion of the drive gear up to the stop.
– After releasing the circlip the ring gear must be locked.
S37-0101
Fitting position of the adjusting washer -F- and

axial needle bearing in the planetary gear
Dimensions of the adjusting washer and of the axial nee-
dle bearing
Bearings Inside ∅ mm Outside ∅ mm

A 22,10 40,00
B 30,00 45,00
C 29,00 48,00
D 18,35 34,50
E 32 to 34 49,50
F 35,30 70,00
A B C D E F
S37-0123
37-10 page 4 Disassembling and assembling planetary gear - Summary of

components
Edition 07.00
S00.5318.00.20
37-11 Disassembling and as-

sembling planetary gear -
Assembly sequence
♦ Engine and gearbox mount -MP 1-202-
♦ Gearbox attachment device -MP 3-478-
♦ Key -T10003-
♦ Assembly stand -MP 9-101-
♦ Catch pan
♦ Sealant -D 176 404 A2-
Disassembling planetary gear

• Gearbox suspended on gearbox suspension device
-MP 3-478- 3
– Position the catch pan under the gearbox. 2 1
N37-0562
– Remove screw plug -1-.
– Remove screw plug -2- and ATF overflow tube -3-.
– Drain the ATF.
– Remove torque converter.
– Release nut -arrow A- for lever/gearshift shaft.
– Remove screws -arrows B- for multi-function switch
from the gearbox.
– Removing electrical connections and sender from
gearbox ⇒ Chap. 01-2. A
S37-0086
B
– Secure gearbox to engine and gearbox mount -MP
1-202- -arrows- and place in assembly stand
-MP 9-101-.
– Remove gearbox suspension device -MP 3-478-.
MP 9-101
MP 1-202 S37-0087
Edition 07.00 Disassembling and assembling planetary gear - Assembly 37-11 page 1
S00.5318.00.20 sequence
– Remove ATF radiator from gearbox -arrow-.
MP 9-101
MP 1-202 S37-0088
– Remove oil pan -arrow-.
S37-0115
– Unclip sender -1- for ATF temperature. C

A
– Disconnect the plug connection -2- to the solenoid A A
valves.
– Unhook the wiring loom from the holder -3-.
– To remove the slide valve body just release the bolts B
marked -arrows A through C- (pay attention to the dif- 2 3 4
ferent lengths when mounting).
When removing the slide valve body the manual slider
-4- remains in the slide valve body.
1 S37-0089
A A
37-11 page 2 Disassembling and assembling planetary gear - Assembly

sequence
Edition 07.00
S00.5318.00.20
– Secure manual slider against dropping out.
– Remove O-rings -A-.
– Unclip cable guide -arrows-, remove wiring loom for
solenoid valves.
N37-0568
– Remove the left and right flange shafts -arrow-.

– Unscrew the fixing bolts (20 pieces) of the converter MP 1-202
housing.
– Remove converter housing.
S37-0090
– Remove the differential -arrow A- from the gearbox

housing.
B
– Remove the O-ring -arrow B- from the gearbox hous- A C
ing.
– Remove the O-ring -arrow C- from the turbine shaft.
N37-0570
S00.5318.00.20 sequence
– Remove the screws -arrows- from the ATF pump.
N37-0573
– Remove gasket -1- of the ATF pump from the flange/

gearbox housing.
– Remove adjusting washer -2- from the reverse gear- 1
clutch -K2-.
N37-0574
– Release lock nut -1- at adjusting screw -2- for brake

band -3-.
– Unscrew adjusting screw.
– Remove brake band. 3
1 2
MP 1-202
S37-0091

sequence
Edition 07.00
S00.5318.00.20
– After removing secure the brake band against spread-
N38-0109
– Remove reverse gear-clutch -1-.
N37-0576
– 1. Remove 1st to 3rd gear clutch -B- with axial needle

bearing -A-.
A B
N37-0577
S00.5318.00.20 sequence
– Remove axial needle bearing -1- from drive shaft -2-.

– Pull out drive shaft.
N37-0578
– Remove needle bearing -A- with large sun gear -B-.
N37-0579
– Remove input shaft -1- from the gearbox housing.
N37-0580

sequence
Edition 07.00
S00.5318.00.20
– Rotate gearbox in assembly stand -MP 9-101- 180°.
– Release the cover screws gradually and crosswise.
MP 1-202
– Remove cover for gearbox housing
S37-0092
– Remove the O-rings -arrows- from the gearbox hous-

ing.
MP 1-202
– 3. Remove 3rd and 4th gear clutch -A- with axial nee-
dle bearing -B-. B A
S37-0093
– Remove axial needle bearing -A- from planet carrier

-B-. A MP 1-202
– Draw out planet carrier.
B
S37-0094
S00.5318.00.20 sequence
– Remove circlip for reverse gear-brake -B1- with a

screwdriver.
MP 1-202
– Remove the washers, pressure plate, plates and
thrust plate of the reverse gear-brake -B1-.
S37-0095
– With a screwdriver straighten the tab of the lock wash-

er of the tensioning screw -A-.
MP 1-202
S37-0096
– Release the tensioning screw from the gearbox hous-

ing.
T10003 MP 1-202
1 - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
S37-0097

sequence
Edition 07.00
S00.5318.00.20
– Remove drive gear with ring gear -A- from the gear-
box housing.
MP 1-202 C
– Remove the circlip -B- for overrunning clutch -C- with
a screwdriver. B
– Draw out overrunning clutch together with the thrust
washer from the gearbox housing. A
– Removing drive gear and ring gear ⇒ Chap. 37-10.
Assembling planetary gear

– Insert the axial needle bearing in the correct fitting po-
sition ⇒ Chap. 37-10. S37-0098
– Assembling drive gear and ring gear ⇒ Chap. 37-10.
– Insert overrunning clutch complete with thrust wash-
ers -C-.
MP 1-202 C
Pay attention to the fitting position when inserting the
overrunning clutch ⇒ Chap. 38-2. B
– Secure overrunning clutch with circlip -B-. A
– Install drive gear with ring gear -A- in the gearbox
housing.
– Insert the new lock washer with the pegs of the wash- S37-0098
er in the gearbox housing holes.
– Tighten tensioning screw to 60 Nm.
T10003 MP 1-202
1 - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
S37-0097
S00.5318.00.20 sequence
– Secure tensioning screw with lock washer.

A MP 1-202
– Insert the planet carrier -B- in the drive gear with ring
gear and simultaneously in the overrunning clutch.
B
Note
When inserting in the overrunning clutch rotate the planet
carrier anti-clockwise (turn left).
– Inspect operation of overrunning clutch:

The planet carrier must only be turned anti-clockwise
(overrunning clutch open).
– Place the axial needle bearing -A- in its fitting location

(black surface remains visible) on the planet carrier S37-0094
-B-.
– Install plates -B1- as follows:
♦ First place a suitable pressure plate ⇒ Chap. 37-12
-5- on the circlip -6-.
♦ Insert inner plates -7- and outer plates -4- of -B1-.
♦ Place thrust plate -3-.
♦ Insert the disc springs -2- in their fitting position (large
diameters point towards one another).
♦ Fit circlip -1-.
1
2
3
7 4
5
6
N38-0106
– 3. Insert the 3rd through 4th gear-clutch -A-. MP 1-202

– Fit new O-rings -arrows- to the gearbox housing.
A
S37-0116

sequence
Edition 07.00
S00.5318.00.20
– Press spring support plate onto the guide studs of the
piston -B1-.
B
One guide stud -A- is thicker than the others and thus
holds the spring support plate in place.
– Moisten the axial needle bearing -B- with ATF to en-

sure the bearing sticks to the gearbox housing cover
when fitted.
Insert the axial needle bearing in its fitting position (black
surface remains visible) on the cover.
– Apply sealant -D 176 404 A2- to the clean sealing sur-

face of the cover.
– The sealant bead must be 3…4 mm thick. A N37-0619
– Fit cover for gearbox housing.
– Subsequently, tighten the screws crosswise with 20
Nm. MP 1-202
– Rotate gearbox in assembly stand -MP 9-101- 180°.
S37-0092
– Insert input shaft -1-.
N37-0580
S00.5318.00.20 sequence
– Insert the large sun gear -B- in the gearbox housing.

– Place the axial needle bearing -A- in its fitting location
(smooth surface remains visible) on the large sun
gear.
N37-0579
– Insert drive shaft -2- in large sun gear.

– Place the axial needle bearing -1- in its fitting location
(black surface remains visible) on the drive shaft.
N37-0578
– 1. Insert the 1st through 3rd gear-clutch -B-.

Insert the axial needle bearing -A- in its fitting position
(black surface remains visible) in the 1st through 3rd
gear-clutch.
When replacing individual components of the planetary
gear, measure the axial needle bearing again ⇒ Chap. B
37-12, adjust clutch clearance.. A
N37-0577

sequence
Edition 07.00
S00.5318.00.20
– Insert reverse gear-clutch -1-.
To do so the recesses -arrow A- of the reverse gear-
1
clutch must catch in the pegs -arrow B- of the large
sun gear.
S37-0099
– Place the adjusting washer -2- on the reverse gear-

clutch -K1-.
When replacing individual components of the planetary 1
gear, measure the adjusting washer again ⇒ Chap. 37-
12, adjust clutch clearance..
– Insert gasket -1- for ATF pump.
N37-0574
Install the brake band as follows:
– Fit brake band -3-.

– Insert new adjusting screw -2- with counternut -1- at
gearbox.
3
Do not yet screw in the coated part of the screw thread.
Final tightening of the adjusting screw must not occur un-
til the ATF pump has been installed ⇒ Chap. 37-12, ad-
just 2nd and 4th gear-brake -B2-.
1 2
MP 1-202
S37-0091
S00.5318.00.20 sequence
– Align ATF pump with gearbox housing. When insert-

ing pay attention to the adjusting washer, gasket for
ATF pump and piston rings of the ATF pump.
– Tighten screws of the ATF pump -arrows- to 20 Nm.
N37-0573
– Insert the differential gear -arrow A-.

– Place new O-rings -arrow B- on the gearbox housing B
and insert in turbine shaft -arrow C-. A C
– Apply sealant -D 176 404 A2- to the clean sealing sur-
face of the converter housing.
The sealant bead must be 3…4 mm thick.
– Position the converter housing on the gearbox hous-

ing, pay attention to the fit pin and O-ring of the ATF N37-0570
pump.
– Tighten the converter housing screws to 30 Nm.
– Install the left and right flange shafts -arrow-. MP 1-202
– Install the plug connection with wiring loom for the so-
lenoid valves.
S37-0090

sequence
Edition 07.00
S00.5318.00.20
– Moisten the O-rings with ATF.
– Insert new O-rings -A- in the gearbox housing.
N37-0617
– Fit slide valve body and insert the bolt of the shift seg- C
ment in the slot of the manual slider -4-. A
A A
– Tighten screws -arrows A through C- by hand, pay at-
tention to the different screw lengths.
♦ Screws -arrows A- = M6 x 80 mm
B
♦ Screw -arrow B- = M6 x 68 mm 2 3 4
♦ Screw -arrow C- = M6 x 40 mm
– Subsequently, tighten the screws gradually and cross-

wise to 8 Nm.
– Insert plug for the solenoid valves -2-.
– Hook wiring loom onto bracket -3-.
– Clip on sender -1- for ATF temperature. 1 S37-0089
A A
Apply sealant -D 176 404 A2- to the oil pan as follows:
– Cut off nozzle tube at the front marking (∅ of nozzle

approx. 3 mm).
– Apply sealant as shown to the clean sealing surface of
the oil pan.
The sealant bead must be 3…4 mm thick.
Run past the area around the bolt holes on the inside
-arrows-.
N17-0019
S00.5318.00.20 sequence
– Install oil pan.

– Install ATF radiator on gearbox -arrow-.
– Installing torque converter ⇒ Chap. 32-1.
– Installing and adjusting multi-function switch ⇒ Chap.
01-2.
– Installing electrical connections and sender on gear-
box ⇒ Chap. 01-2.
– Installing gearbox ⇒ Chap. 34-7. MP 9-101
– Subsequently fill ATF and check ATF level and top up
⇒ Chap. 34-8.
Tightening torques
MP 1-202 S37-0088
Oil pan to gearbox housing 8 Nm
ATF radiator to gearbox housing 25 Nm
Flange shaft to gearbox (conical 22 Nm
screw)
Gearshift shaft lever to gearbox 17 Nm

sequence
Edition 07.00
S00.5318.00.20
37-12 Adjusting work on planetary gear
Overview
I - Reverse gear-brake -B1-
T A - pressure plate
– Determine the thickness A B
⇒ 37-12 page 2
II - 2. 2nd and 4th gear-brake -B2-
T B - brake band
– Setting brake band ⇒ 37-12 I II
page 4
III - Clutch clearance
T C - axial needle bearing
– Determine the thickness
⇒ 37-12 page 6
T D - adjusting washer
– Determine the thickness
⇒ 37-12 page 6
III
C D
N37-0603
Edition 07.00 Adjusting work on planetary gear 37-12 page 1

S00.5318.00.20
Adjusting reverse gear-brake -B1-

Special tools, test and measuring equipment and aids required
♦ Feeler gauge
– Install components for adjusting the reverse gear-brake -B1- in the gearbox housing ⇒ Chap. 37-11.
1 - Gearbox housing
2 - Circlip
T for overrunning clutch
3 - Pressure plate
T install to set
T after measuring install deter-
mined thickness 1
4 - Inner plate -B1-
T Pieces ⇒ Chap. 00-1
5 - Outer plate -B1- 7 2
6 - Thrust plate 3
7 - Disc spring
4
T Check fitting position: large
diameters face one another 5
8 - Circlip
8 4
9 - Spring support plate
T with springs
5
10 - Cover for gearbox housing 4
T with -B1- piston
9
5
T before removing or installing
the cover remove the vehicle 4
speed sender -G68- 10 6
⇒ Chap. 01-2
11 - 20 Nm
11
N37-0604
37-12 page 2 Adjusting work on planetary gear Edition 07.00

S00.5318.00.20
Pressure plate -A- to be measured
– Install all components for adjusting the reverse gear-
brake -B1- in the gearbox housing ⇒ 37-12 page 2.
N37-0590
– Tighten the screws of the cover to the gearbox hous-

ing to 20 Nm.
N37-0581
– Blow compressed air into the pressure channel -ar-

row-. The piston must be heard to compress the plate
packet. Without compressed air the piston must return
to rest position.
N37-0591

S00.5318.00.20
– With a feeler gauge -A- measure the clearance be-

tween the circlip -1- and the pressure plate -2-.
Clearance:
min. = 0.8 mm
max. = 1.1 mm 1
N37-0592
A
2. Adjust 2nd and 4th gear-brake -B2-

– Installing components for setting the 2nd and 4th gear-brake -B2- ⇒ Chap. 37-11.
1 - Gearbox housing
T Planetary gear fitted up to re-
verse gear-clutch -K2-
1
⇒ Chap. 37-11
2 - Adjusting screw
T for brake band -B2- 3 2
T always replace 5 4
7 6
T bring to system in moulded
part of the brake band -B2-
3 - 45 Nm
4 - Brake band -B2-
5 - Gasket
T for ATF pump
6 - ATF pump
7 - 20 Nm
8 - Spring
9 - Spring
10 - Control piston 2nd and 4th
gear brake 8
T Insert pressure rod in the
moulded part of the brake 9
band
11 - Cover 10
12 - Circlip
11
12
N37-0605

S00.5318.00.20
– Tighten screws of the ATF pump -arrows- to 20 Nm.
N37-0573
Adjusting brake band -3-:
– Tighten adjusting screw -2- to 5 Nm.

– Turn adjusting screw back 2.5 turns.
3
– Tighten nut -1- to 45 Nm, while doing so prevent ad-
justing screw from turning along.
1 2
MP 1-202
S37-0091

S00.5318.00.20
Setting clutch clearance

♦ Gauge block plate -MP 3-0405/17-
♦ Universal dial gauge holder -MP 3-447-
♦ Depth gauge
♦ Straightedge
♦ Dial gauge
– Installing components for adjusting the clutch clearance without axial needle brearing -Pos. 3-, adjusting washer
-Pos. 5- and ATF pump -Pos. 7- ⇒ Chap. 37-11.
– Set clutch clearance between -K1- and ATF pump ⇒ 37-12 page 7
– Set clutch clearance between -K2- and ATF pump ⇒ 37-12 page 8
– Perform control measurement (clutch clearance) ⇒ 37-12 page 10
1 - Gearbox housing
T Planetary gear fitted up to
small drive shaft ⇒ Chap.
37-11 3 2
2 - 1. 1st through 3rd gear clutch
5 4
-K1- with turbine shaft 8 7 6
3 - Axial needle bearing with
washer
T Observe the fitting position
⇒ Chap. 37-10
T do not install to adjust the
clutch clearance
4 - Reverse gear-clutch -K2-
T do not install to adjust the
clutch clearance 1
6 - Gasket
T for ATF pump
7 - ATF pump
8 - 20 Nm
N37-0606

S00.5318.00.20
Set clutch clearance between -K1- and ATF
pump
Determine thickness of the axial needle bearing -A-
The thickness of the axial needle bearing is determined
by gap size -x- and must be selected according to the ta- D 1
ble ⇒ 37-12 page 8
Gap size x = a - b
A- Axial needle bearing (not fitted for measuring)
D- Gasket
1- ATF pump
3- 1. 1st through 3rd gear clutch -K1- a b
4
4- Gearbox housing
3 x A
N37-0607
determining a:
B A
– Place straightedge -A- on the gearbox housing.
– Measure on -K1- with depth gauge -B-.
Example:
Measured value 1 = 54.8 mm
N37-0608
– Place gasket -C- on the pump flange of the gearbox

housing. B A
– Measure on pump flange at gearbox housing with
depth gauge -B-.
Example:
Measured value 1 = 54.8 mm C

- Measured value 2 = -23.2 mm
determined value a = 31.6 mm
N37-0597

S00.5318.00.20
determining b:
– Place straightedge -B- on the ATF pump.

– Measure on pump flange with depth gauge -A-. A B
– Example:
measured value = 33.8 mm

- Straightedge = -5.7 mm
determined value b = 28.1 mm
Gap size x = a - b
= 31.6 mm - 28.1 mm = 3.5 mm
N37-0598
– Determine thickness of the axial needle bearing ac-
cording to the table and refer to the spare part cata-
logue to determine the spare part number.
Axial needle bearing table:
Gap size -x- (mm) Axial needle bearing

(mm)
2,95…3,14 2,70
D 1
3,15…3,34 2,90
3,35…3,54 3,10
3,55…3,74 3,30
3,75…3,94 3,50
3,95…4,14 3,70 d c y
B
Set clutch clearance between -K2- and ATF
pump 4
Determining the thickness of the adjusting washer
-B-
3
The thickness of the adjusting washer is determined by
gap size -y- and must be selected according to the table
⇒ 37-12 page 10 2
Gap size y = c + d
B- Adjusting washer (not fitted for measuring) N37-0611
D- Gasket
1- ATF pump
3- 1. 1st through 3rd gear clutch -K1- A B
4- Gearbox housing
determining c:
– Place straightedge -A- on the ATF pump.

– Measure on pump housing with depth gauge -B-.
Example:
N37-0599

S00.5318.00.20
– Measure on pump flange with depth gauge -A-.
Example:
A B

- Measured value 2 = -33.8 mm
determined value c = 0.2 mm
N37-0598
determining d:
A B
– Measure on thrust collar of the reverse gear-clutch -
K2- with depth gauge -B-.
Example:
N37-0600
– Place gasket -C- on the pump flange of the gearbox

housing. B A
– Measure on pump flange at gearbox housing with
depth gauge -B-.
Example:

- Measured value 2 = -23.2 mm C
determined value d = 1.5 mm
Gap size y = c + d
N37-0597
= 0.2 mm + 1.5 mm = 1.7 mm
– Determine thickness of the adjusting washer accord-

ing to the table and refer to the spare part catalogue
to determine the spare part number.

S00.5318.00.20
Table of adjusting washers:
Gap size -y- (mm) Adjusting washers (mm)

1,35…1,54 0,80
1,55…1,74 1,00
1,75…1,94 1,20
1,95…2,14 1,40
2,15…2,34 1,60
2,35…2,54 1,80
2,55…2,74 2,00
2,75…2,94 2,20
– Perform control measurement of the clutch clearance

after fitting the ATF pump ⇒ 37-12 page 10
Control measurement (clutch clearance)

– Clutch clearance can only be measured after installing
the ATF pump.
– Attach universal dial gauge holder to the gearbox
housing and place dial gauge with 1 mm bias on the
turbine shaft.
– Move turbine shaft up and down and read off clear-
ance on the dial gauge.
MP 3-447
Clearance:
min. = 0.25 mm MP 3-405/17
max. = 0.55 mm
S37-0102

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38 – Wheels, Control
38-1 Disassembling and assembling the ATF pump

♦ Measuring device -MP 3-0404/7-
♦ Feeler gauge
♦ Dial gauge
1 - Piston ring
T check correct fitting
T do not over-extend 1
2 - 10 Nm
3 - Cover for ATF pump
4 - Outer gear 2
T check for wear ⇒ Fig. 1 in
38-1 page 2 and ⇒ Fig. 2 in
38-1 page 2
3
5 - Inner gear
T check for wear ⇒ Fig. 1 in
38-1 page 2 and ⇒ Fig. 2 in
38-1 page 2 4
6 - Housing for ATF pump
7 - O-ring
T always replace 5
8 - Gasket ring for torque con-
verter
⇒ Chap. 32-1 6
8
N38-0083
Edition 07.00 Disassembling and assembling the ATF pump 38-1 page 1
S00.5318.00.20
Fig. 1: Measure the axial wear of the outer and in-

ner gear to the ATF pump housing
– Place the measuring device on the ATF pump hous-

ing.
– If the measured value is greater than the wear limit in MP 3-404/7
the table replace the relevant gear.
Measuring point Wear limit mm

Height difference between the ATF 0,04
pump housing and outer gear
Height difference between the ATF 0,04
pump housing and inner gear
S38-0019
Fig. 2: Measure play between the outer and inner

gear
A - Feeler gauge 0.5 mm A
– If the 0.5 mm feeler gauge can be inserted between
the outer and inner gear, replace the gears.
N38-0085
38-1 page 2 Disassembling and assembling the ATF pump Edition 07.00
S00.5318.00.20
38-2 Disassembling and assembling overrunning clutch

1 - Thrust washer
T place on clamp body cage
⇒ item 2
T smooth side facing outwards
1
2 - Clamp body cage
T install in outer gear for over-
running clutch ⇒ Fig. 1 in
38-2 page 2
3 - Outer gear for overrunning
clutch
T Fitting position: Logo and
chamfer -arrow- point to- 2
wards planet carrier
N38-0086
Edition 07.00 Disassembling and assembling overrunning clutch 38-2 page 1

S00.5318.00.20
Fig. 1: Assemble overrunning clutch
– Lay the outer ring -arrow C- with chamfer -arrow B- A

pointing downwards on the work table.
– Lay the clamp body cage -arrow D- with the conical
guide lugs -arrow A- pointing downwards on the outer
ring.
– Press clamp body inwards while pushing the cage
over the guide lugs in the outer ring.
– Lay the thrust washers on the clamp body cage.
– Inspect operation of overrunning clutch: B
♦ Lay aside overrunning clutch in fitting position (logo
and chamfer pointing upwards).
♦ Place the planet carrier in the clamp body cage.
Turn planet carrier to the left: Overrunning gear open C

Turn planet carrier to the right: Overrunning gear blocks D
S38-0031
38-2 page 2 Disassembling and assembling overrunning clutch Edition 07.00

S00.5318.00.20
38-3 1. Disassembling and assembling 1st through 3rd gear clutch

-K1-
♦ Pressure plate -MP 3-406-
♦ Thrust piece -MP 3-408-
♦ Sleeve -MP 3-486/1-
♦ Pipe -MP 6-419-
♦ Feeler gauge
Inspect operation of clutch ⇒ Fig. 3 in 38-3 page 2
1 - Circlip
T release with a screwdriver 6
2 - Pressure plate
T installing ⇒ Fig. 2 in 38-3 7 1
page 2
T Determine the thickness 2
⇒ Fig. 4 in 38-3 page 3 8
3 - Inner plate 3
T installing ⇒ Fig. 2 in 38-3
page 2 9 4
4 - Outer plate
10 3
page 2
11 4
5 - Disc spring
3
page 2
12
T curved side (smaller diame-
4
ter) points to clutch bell
6 - Circlip 3
⇒ Fig. 1 in 38-3 page 2 4
7 - Gasket ring 13
T always replace 3
8 - Piston cap
T moisten gasket rings with 4
ATF before inserting
9 - Spring 5
T insert between piston and 14
piston cap N38-0088
10 - Gasket ring
T always replace
T Sealing lip points towards clutch bell
11 - Gasket ring
T always replace
12 - Piston
T differs depending on the engine version
T moisten sealing lips with ATF before inserting
T turn piston slightly when installing
T after installing the piston must turn in the clutch bell
Edition 07.00 1. Disassembling and assembling 1st through 3rd gear clutch -K1- 38-3 page 1
S00.5318.00.20
13 - Clutch bell with turbine shaft

14 - Piston ring
T do not over-extend
Fig. 1: Removing and installing circlip
– Press the piston cap with spring down until the circlip
-arrow- can be inserted in the groove. MP 3-408
MP 6-419
MP 3-486/1
MP 3-406
S38-0020
Fig. 2: Installing outer and inner plates
– Lay the outer plates -2- and inner plates -4- on the disc 1 2 3
spring -3-.
– Lay the pressure plate -5- on the last inner plate.
– Insert the circlip -1- in the groove of the clutch bell.
5 4 N38-0090
Fig. 3: Inspect operation of clutch
– With a pneumatic gun blow air in the pressure channel

-arrow-.
– Shut off the hole on the opposite side.
– The clutch piston must compress the plate packet.
– Allow compressed air to escape. The clutch packet
must again return to its rest position.
N38-0091
38-3 page 2 1. Disassembling and assembling 1st through 3rd gear clutch -K1- Edition 07.00
S00.5318.00.20
Fig. 4: Determine the thickness of the pressure
plate.
– Measure the clearance between the pressure plate

and the circlip with a feeler gauge -A-.
A
Component Fitting dimen- Wear limit

sion
Clutch -K1- 0,45…0.85 mm 1.05 mm
– If the wear limit is reached on a used clutch, replace

the plates and measure a new pressure plate.
– Assign the plates and pressure plate according to the
N38-0092
Edition 07.00 1. Disassembling and assembling 1st through 3rd gear clutch -K1- 38-3 page 3
S00.5318.00.20
38-3 page 4 1. Disassembling and assembling 1st through 3rd gear clutch -K1- Edition 07.00
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38-4 Disassembling and assembling the reverse gear-clutch -K2-

♦ Pressure plate -T10002-
♦ Feeler gauge
1 - Circlip
T mark after removing and in-
stall again in same position
2 - Pressure plate
5 1
page 2
T Determine the thickness
⇒ Fig. 4 in 38-4 page 3 6
3 - Inner plate 2
page 2
4 - Outer plate
T installing ⇒ Fig. 2 in 38-4 7 3
page 2
5 - Circlip 8
T release with a screwdriver
T installing ⇒ Fig. 1 in 38-4 4
page 2
6 - Spring support plate 9
T with springs
page 2 3
7 - Gasket ring
T always replace
T Sealing lip points towards
clutch bell 10 4
8 - Gasket ring
T always replace
9 - Piston N38-0093
T moisten sealing lips with ATF
before inserting
T Sealing lip points towards clutch bell
10 - Clutch bell
Edition 07.00 Disassembling and assembling the reverse gear-clutch -K2- 38-4 page 1
S00.5318.00.20
Fig. 1: Install circlip
– Place the spring support plate on the piston of the -K2- MP 3-448
clutch.
– Lay circlip on the spring support plate. T10002
– Carefully press the circlip with spring support plate
over pressure plate -T10002-, until the circlip is heard
to click into the groove.
MP 3-407
S38-0021
– Install the outer plates -3- and inner plates -4- in the 1 2 3
clutch bell.
– Insert the circlip -1- in the groove of the clutch bell.
N38-0095
– Place adjusting washer between -K2- clutch and ATF

pump.
– Place clutch -K2- on the ATF pump and press down-
wards.
-arrow-.
N38-0096
38-4 page 2 Disassembling and assembling the reverse gear-clutch -K2- Edition 07.00
S00.5318.00.20
plate
– Measure the clearance between the pressure plate A

and the circlip with a feeler gauge -A-.

sion
Clutch -K2- 0.5…0.8 mm 1.0 mm

N38-0097
Edition 07.00 Disassembling and assembling the reverse gear-clutch -K2- 38-4 page 3
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38-4 page 4 Disassembling and assembling the reverse gear-clutch -K2- Edition 07.00
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38-5 Disassembling and assembling 3rd and 4th gear-clutch -K3-

Already when assembling, pay attention⇒ Fig. 2 in 38-5 page 2 to the number of plates and their fitting position
♦ Bushing -MP 3-486/1-
♦ Feeler gauge
1 - Circlip
2 - Pressure plate
page 2
T Determine thickness
⇒ Fig. 5 in 38-5 page 3
3 - Inner plate
page 2
4 - Outer plate
page 2
5 - Circlip
⇒ Fig. 1 in 38-5 page 2
T with springs
7 - Gasket ring
T always replace
8 - Gasket ring
T always replace
9 - Piston
T differs depending on the en-
gine version
T assigned to gearbox identifi-
cation characters as a spare
part
T moisten sealing lips with ATF
before inserting
10 - Clutch bell
Edition 04.05 Disassembling and assembling 3rd and 4th gear-clutch -K3- 38-5 page 1
S00.5318.02.20
Fig. 1: Removing and installing circlip -arrow-
– Carefully press down piston cap until the circlip can be

removed or installed. MP 3-408
MP 3-486/1
MP 3-407
S38-0022
Fig. 2: Pay attention to the different number and fit-

ting position of the plates
– fig.I -K3- with 3 inner plates

– fig.II -K3- with 4 inner plates
– A - circlip
– B - pressure plate

4
– Install the outer plates -4- and inner plates -3- in the
clutch bell.
– Insert the circlip -1- in the groove of the clutch bell. 1
3
N38-0100
38-5 page 2 Disassembling and assembling 3rd and 4th gear-clutch -K3- Edition 04.05
S00.5318.02.20
– Lay the axial needle bearing on the cover for the gear-
box housing.
– Place clutch -K3- on the cover of the gearbox housing
and press downwards.
-arrow-.
N38-0101

plate.
– Measure the clearance between the pressure plate

and the circlip with a feeler gauge -A-. A
sion
Clutch -K3- 1,8…2.2 mm 2.4 mm

N38-0102
Edition 04.05 Disassembling and assembling 3rd and 4th gear-clutch -K3- 38-5 page 3
S00.5318.02.20
38-5 page 4 Disassembling and assembling 3rd and 4th gear-clutch -K3- Edition 04.05
S00.5318.02.20
38-6 Disassembling and assembling the reverse gear-brake -B1-

1 - Gearbox housing
2 - Circlip
3 - Pressure plate
page 2
T Determine thickness 1
⇒ Chap. 37-12
4 - Inner plate -B1-
9 2
5 - Outer plate -B1- 3
page 2 4
T Pieces ⇒ Chap. 00-1 5
6 - Thrust plate 11 4
7 - Disc spring
T Check fitting position: large 5
diameters face one another 12 4
⇒ Fig. 3 in 38-6 page 2
8 - Circlip
13 5
T release with a screwdriver 14 4
T with springs 6
T press onto piston ⇒ item 12
⇒ Fig. 2 in 38-6 page 2
10 - Gasket ring
7
T always replace 8
11 - Gasket ring 16 15
T always replace
16
12 - Piston -B1- N38-0103
gine version
T moisten gasket rings with ATF before inserting
13 - Piston ring
T do not over-extend
14 - Cover for gearbox housing
15 - O-ring
T always replace
16 - Plug screw
Edition 07.00 Disassembling and assembling the reverse gear-brake -B1- 38-6 page 1
S00.5318.00.20
Fig. 1: Remove piston -B1-
– With a screwdriver lever off piston from gearbox hous-

ing cover.
N38-0104
Fig. 2: Place spring support plate on the piston -

B1-
– Press spring support plate onto the guide studs of the

piston -B1-.
One guide stud -A- is thicker than the others and thus
holds the spring support plate in place.
A N38-0105
– Lay pressure plate -5- on circlip -6-, which holds the

overrunning clutch in position.
– Install the outer plates -4- and inner plates -7- in the
gearbox housing.
– Lay the thrust plate -3- on the last inner plate.
– Insert the disc springs -2- in their correct fitting posi-
tion, large diameters point towards one another.
– Insert the circlip -1- in the groove of the gearbox hous- 1
ing.
2
3
7 4
5
6
N38-0106
38-6 page 2 Disassembling and assembling the reverse gear-brake -B1- Edition 07.00
S00.5318.00.20
38-7 Disassembling and assembling the piston for 2nd and 4th
gear-brake -B2-
♦ Screw clamp, commercially available
♦ Wire hanger, self-made
1 - Circlip
⇒ Fig. 1 in 38-7 page 2
2 - O-ring 16
T always replace
3 - O-ring 15
T always replace
4 - Cover
14
T after removing circlip pull out 13
of gearbox housing
5 - O-ring
T always replace
6 - 4. Gear-control piston
gine version
T assigned to gearbox identifi- 9 12
part 11
7 - O-ring
8
10
T always replace
8 - O-ring
7
T always replace 6
9 - Piston cap
T for 2nd gear-control piston 5
gine version 4
T assigned to gearbox identifi-
part 3 2 1
10 - 2. Gear-control piston
S38-0023
gine version
11 - Spring
12 - Spring
13 - Brake band -B2-
T lay aside in fitting position ⇒ Fig. 2 in 38-7 page 2
14 - Adjusting screw
15 - 45 Nm
Edition 07.00 Disassembling and assembling the piston for 2nd and 4th gear- 38-7 page 1
S00.5318.00.20 brake -B2-
Fig. 1: Removing and installing circlip
– Place the pressure plate -MP 3-453- over the piston A

body of the control piston for brake -B2-.
– Pretension cover with screw clamp -A-.
– Lever off circlip with screwdriver -B-. MP 3-453
B
S38-0024
Fig. 2: Laying aside brake band -B2-
– After removing secure the brake band against spread-

N38-0109
38-7 page 2 Disassembling and assembling the piston for 2nd and 4th gear-
brake -B2-
Edition 07.00
S00.5318.00.20
38-8 Removing and installing slide valve body - Summary of com-

ponents
Mounting sequence ⇒ Chap. 37-11
Caution!
Do not run the engine or tow the vehicle when the oil pan of the gearbox has been removed or without ATF
filling.
Note
♦ The slide valve body or wiring loom can also be removed when the gearbox is installed.
♦ The solenoid valves can be replaced.
♦ Do not use fluffing cloths.
♦ After re-installing the oil pan check ATF level and top up ⇒ Chap. 37-8.

♦ Torque wrench (5..0,50 Nm), e.g. -V.A.G 1331-
♦ Catch pan
1 - Screw plug, 15 Nm
T Always replace gasket ring 9 10 11 12 13
⇒ Fig. 1 in 38-8 page 2
T Checking ATF level and top- 14
ping up ⇒ Chap. 37-8
15
2 - Overflow tube
T remove to drain ATF 18
⇒ Chap. 37-11
16
17
3 - 8 Nm
4 - Oil pan 19
8
⇒ Chap. 37-11
1
5 - Magnet
T insert on oil pan supports 2
6 - 8 Nm 20
T for ATF strainer on slide
valve body 3 25
7 - ATF strainer
T to replace remove and install 24
the oil pan 4
23
T removing and installing 21
⇒ 38-8 page 3
8 - Retaining plate with solenoid 5
valves -N88- through -N92- 22
T replace jointly
⇒ 38-8 page 4
9 - 8 Nm
T M6 x 35 mm
10 - 8 Nm 7 6
T M6 x 68 mm S38-0025
11 - 8 Nm
T M6 x 12 mm
Edition 07.00 Removing and installing slide valve body - Summary of 38-8 page 1
12 - Solenoid valve -N93-

T pink
T removing and installing ⇒ 38-8 page 3
13 - 8 Nm
T M6 x 75 mm
14 - Spacer
T insert in grommet ⇒ item 15
15 - Grommet
T insert in solenoid valve -N93- ⇒ item 12
16 - Sealing ring
T always replace
17 - Sealing ring
T always replace
18 - 8 Nm
T for slide valve body on the gearbox housing
T pay attention to the different screw lengths ⇒ Chap. 37-11
19 - Slide valve body
T Identification ⇒ Fig. 2 in 38-8 page 3
20 - Manual slider
T secure against dropping out when removing the slide valve body
21 - Sealing ring
T always replace
23 - Plug connector
T for wiring loom
T removing ⇒ Chap. 37-11
T when installing lock in gearbox housing
24 - Sealing ring
T always replace
T for plug connection/wiring loom
25 - Wiring loom
T for solenoid valve
Fig. 1: Replace the gasket ring of the screw plug
– Cut open gasket ring -arrow- with side cutter, always

replace gasket ring.
– After repair screw in screw plug with new gasket ring
to add ATF.
– Subsequently fill ATF and check ATF level and top up
⇒ Chap. 37-8
N38-0037
38-8 page 2 Removing and installing slide valve body - Summary of

components
Edition 07.00
S00.5318.00.20
Fig. 2: Slide valve body identification
Identification characters are embossed in identification
tag -arrow-. The identification tag must remain with the
slide valve body.
Removing and installing ATF strainer
Removing
S38-0026
– Removing oil pan ⇒ Chap. 37-11.
– Release the screws -arrows A and B-. A
A B
Note
Do not interchange the screws -arrows A and B-. Insert in 3
same location when re-installing.
B
Installing
1 B
– Install holder -1- for plug connection, holder -2- for wir- 2
ing loom and identification tag -3- as shown in Fig.
– Tighten screws -arrows A and B- by hand.
– Subsequently, tighten screws gradually crosswise to 8 B
Nm. B B
– Installing oil pan ⇒ Chap. 37-11. B S38-0029
Solenoid valve -N93-
Removing
– Release screw -1- and remove wire for solenoid valve
from screw.
– Release screws -arrows-.
– Release connector -2-.
– Pull out solenoid valve -3-.
Installing
– Always replace the O-rings of the solenoid valve.

– Tighten screw -1- (M6 x 35 mm) and screws -arrows-
(M6 x 75 mm) to 8 Nm. 1 2 3 S38-0028
– Installing oil pan ⇒ Chap. 37-11.
Edition 07.00 Removing and installing slide valve body - Summary of 38-8 page 3
Removing and installing retaining plate

with solenoid valves -N88- through -N92-
Removing
– Remove solenoid valve -N93- ⇒ 38-8 page 3.
– Disconnect the plug connection -1- for solenoid valves C
and remove plug from holder. B
– Release the screws -arrows A through C-. B
Note
Do not interchange screws -arrow A- (M6 x 35 mm), -ar- B 1
rows B- (M6 x 68 mm) and -arrow C- (M6 x 12 mm). In- B
sert in same location when re-installing.
Installing A
The installation occurs in reverse order. 2
– Tighten screws -arrows A through C- to 8 Nm. S38-0027
– Install solenoid valve -N93- ⇒ 38-8 page 3.

– Installing oil pan ⇒ Chap. 37-11.
38-8 page 4 Removing and installing slide valve body - Summary of

components
Edition 07.00
S00.5318.00.20
38-9 Disassembling and assembling the parking position

Note
To disassemble and assemble the parking position it is necessary to remove the input shaft with parking position gear
and the slide valve body.
1 - Gasket ring
T for gearshift shaft
T removing ⇒ Fig. 1 in 38-9
16 17
page 2
page 2
2 - Gearshift shaft
⇒ Fig. 3 in 38-9 page 2
T when transporting the gear-
box avoid axial impact 14 15
shocks to the gearshift shaft,
screw ⇒ item 3 could be
sheared off
3 - 10 Nm 1
T locks the gearshift shaft in
13 2
the gearbox housing
4 - Spring for shift segment
T do not over-press
5 - 5 Nm 11 12
6 - Shift segment 3
7 - Tensioning sleeve 10
T for shift segment 4
T drive out with drift
5
T drive in after inserting the
shift segment ⇒ Fig. 3 in
38-9 page 2
8 - Tensioning sleeve
T with lever ⇒ item 9
9
T drive in after inserting the
8 7 6 N38-0123
shift segment ⇒ Fig. 3 in
38-9 page 2
9 - Lever
T assemble with engaging lever ⇒ item 10 before installing on gearshift shaft
10 - Engaging lever
T position on gearshift shaft together with lever
11 - 27 Nm
12 - Support plate
T for engaging lever
13 - 5 Nm
14 - Cover plate
T secures axle for locking lever
Edition 07.00 Disassembling and assembling the parking position 38-9 page 1
S00.5318.00.20
15 - Axle for locking lever

T can be removed and installed by hand
16 - Retracting spring
17 - Locking lever
Fig. 1: Removing gasket ring for gearshift shaft
N38-0056
Fig. 2: Driving in gasket ring for gearshift shaft
– When installing a new gasket ring moisten the space

between the sealing lip and dust lip with ATF.
T30030
– Drive in gasket ring with pressure plate -T30030- up to
the stop.
S38-0030
Fig. 3: Driving the tensioning sleeves -1- in and out

Driving out
– Drive out the tensioning sleeves -1- for lever -4- and
gearshift segment -5- until the gearshift shaft -2- can
be pulled out.
Driving in 4 5
– After inserting the gearshift shaft in the shift segment
and lever, drive in the tensioning sleeves until flush.
– Lock gearshift shaft with screw -3-. 1 1
3 2 N38-0125
38-9 page 2 Disassembling and assembling the parking position Edition 07.00
S00.5318.00.20
Fig. 4: Removing and installing the locking lever
-3- with retracting spring
– Unscrew plug -arrow-. 1

– Remove cover plate -1- and pull out axle for locking le-
ver.
– Remove retracting spring -2- and locking lever.
– When installing hook the leg of the retracting spring
into the locking lever and allow the other extremity of
the spring to rest against the gearbox housing.
2
3
N38-0126
Edition 07.00 Disassembling and assembling the parking position 38-9 page 3
S00.5318.00.20
38-9 page 4 Disassembling and assembling the parking position Edition 07.00
S00.5318.00.20
39 – Final drive, differential
39-1 Replacing flange shaft

gasket rings
♦ Catch pan
♦ Sealant -D 176 404 A2-
Removing
– Remove noise insulation below engine/gearbox

⇒ Engine, Mechanics; Rep. Gr. 10.
♦ Before replacing left gasket ring:
– Removing drive shaft ⇒ Running Gear; Rep. Gr. 40.

♦ Before replacing right gasket ring:
– Turn steering to full right lock.

– Unscrew the drive shaft from the flange shaft.
– Tie up the drive shaft as far as possible. Avoid dam-
aging the paintwork on the drive shaft during this op-
eration. T30033
♦ Proceed as follows for both gasket rings:

– Release fixing screw for flange shaft, to do so secure
flange against turning.
– Remove the flange shaft with pressure spring.
– Pull out gasket ring for flange shaft with ejection lever
-MP 3-418-. S39-0198
– Drive the new gasket ring in up to the stop, do not twist
the gasket ring.
– Moisten the space between the sealing lip and dust lip
with ATF.
– Coat screw head of conical screw with sealant
-D 176 404 A2-.
– Install flange shaft, tighten screw to 22 Nm.
Note
♦ The lengths of the left and right flange shafts differ.
Do not interchange.
♦ Only remove and install one flange shaft in order to
prevent the large differential bevel gears in the differ-
ential gear from turning.
Edition 07.00 Replacing flange shaft gasket rings 39-1 page 1

S00.5318.00.20
– Screw the left drive shaft or right drive shaft to the

flange shaft.
– With the gearbox installed check ATF level and top up
⇒ Chap. 37-8.
Tightening torques
Flange shaft to gearbox (conical 22 Nm

screw)
Tighten drive shaft to flange shaft I - 10 Nm
diagonally across in 2 steps (I and II) II - 40 Nm
to M81)
1) Always replace these bolts
39-1 page 2 Replacing flange shaft gasket rings Edition 07.00

S00.5318.00.20
39-2 Disassembling and assembling the final drive
Repair overview of the final drive

1 - Planetary gear
bling ⇒ Chapter 37-10
1
2 - Drive pinion
bling ⇒ 39-2 page 2
T setting ⇒ Chapter 39-3
T Adjusting final drive (over-
view) ⇒ Chap. 39-3
T Number of teeth ⇒ Chap.
00-1
3 - Differential
bling ⇒ 39-2 page 7
T setting ⇒ Chapter 39-3
T Adjusting final drive (over- 2
view) ⇒ Chap. 39-3
4 - Output gear
T removing and installing 5 3
⇒ 39-2 page 2
5 - Input gear
⇒ Chapter 37-10 4
N39-0444
Edition 04.05 Disassembling and assembling the final drive 39-2 page 1
S00.5318.02.20
Disassembling and assembling the input shaft

♦ Pipe section -MP 3-414-
♦ Pressure washer -MP 3-456-
♦ Distance sleeve -MP 3-458-
♦ Washer -MP 6-415-
♦ Tapered-roller bearing extractor, e.g. -V.A.G 1582- or gripper -V.A.G 1582/7-
♦ Interior extractor 46...58 mm, e.g. -Kukko 21/7-
♦ Countersupport, e.g. -Kukko 22/2-
Note
To remove the input shaft, first remove the planetary gear up to the large sun gear after removing the torque converter
housing ⇒ Chap. 37-10.
1 - Torque converter housing

T Determine thickness
⇒ Chapter 39-3
3 - Outer ring/tapered-roller bear- 1 6
ing
T removing ⇒ Fig. 1 in 39-2
page 3
page 3
4 - Inner ring/tapered-roller bear-
ing 8
T remove ⇒ Fig. 3 in 39-2
page 4 2
T pressing on ⇒ Fig. 4 in 39-2 9
page 4
5 - Drive pinion 3
T Number of teeth ⇒ Chap. 10
00-1
T setting ⇒ Chapter 39-3 4
6 - Parking position gear 11
7 - Output gear
T Number of teeth ⇒ Chap. 5
00-1
T pressing off ⇒ Fig. 5 in 39-2
page 4
T pressing on ⇒ Fig. 6 in 39-2
page 5
8 - 145 Nm
T always replace
T loosen and tighten ⇒ Fig. 11 N39-0446
in 39-2 page 6
39-2 page 2 Disassembling and assembling the final drive Edition 04.05
S00.5318.02.20
T secure ⇒ Fig. 12 in 39-2 page 7
9 - Inner ring/tapered-roller bearing
T remove ⇒ Fig. 7 in 39-2 page 5
T pressing on ⇒ Fig. 8 in 39-2 page 5
10 - Outer ring/tapered-roller bearing
T installing ⇒ Fig. 10 in 39-2 page 6
Fig. 1: Remove outer ring/tapered-roller bearing

from torque converter housing
A - Countersupport, e.g. -Kukko 22/2- A
B - Interior extractor 46...58 mm, e.g. -Kukko 21/7-
N39-0447
Fig. 2: Press in outer ring/tapered-roller bearing in

the torque converter housing
MP 3-456
S39-0165
S00.5318.02.20
Fig. 3: Removing inner ring/tapered-roller bearing
V.A.G 1582
V.A.G 1582/7
N39-0449
Fig. 4: Pressing on inner ring/tapered-roller bear-

ing
MP 3-414
MP 3-406 MP 3-407
S39-0166
Fig. 5: Press off output gear

MP 3-448
MP 3-407 MP 3-406
S39-0170
S00.5318.02.20
Fig. 6: Press on output gear
MP 3-408
MP 3-458
MP 3-407
S39-0171
V.A.G 1582
V.A.G 1582/7
N39-0506

ing
MP 3-414
MP 3-407
S39-0167
S00.5318.02.20
Fig. 9: Remove outer ring/tapered-roller bearing

from gearbox housing
A
A - Countersupport, e.g. -Kukko 22/2-
B - Interior extractor 46...58 mm, e.g. -Kukko 21/7-
B
N38-0129
Fig. 10: Press outer ring/tapered-roller bearing into

the gearbox housing
– Support the gearbox housing with pressure plate MP 3-423

-MP 3-4014 -, directly under the bearing support as
shown in the Fig.
MP 6-415
MP 3-4014
MP 3-407
S39-0168
Fig. 11: Loosen and tighten hexagon nut
– Secure input shaft near the parking position gear in a

vice fitted with protective jaws -A-.
– Open catches on the nut ⇒ -arrows- in Fig. N39-0458
⇒ Fig. 12 in 39-2 page 7
B
B - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
N39-0457
S00.5318.02.20
Fig. 12: Secure hexagon nut
– Secure the collar of the hexagon nut with drift in the re-
cessed slots of the input shaft -arrows-.
N39-0458
Disassembling and assembling the differential

♦ Drive bushing -MP 3-427-
♦ Pipe section -MP 3-450-
♦ Alignment rails -MP 3-457-
♦ Thrust plate -MP 3-464-
♦ Assembly device -MP 5-400-
♦ Pressure pipe -MP 6-408-
♦ Drawing ring -T30036/3-
♦ Tapered-roller bearing extractor, e.g. -V.A.G 1582- or gripper -V.A.G 1582/3-
♦ Two-arm extractor 46...58 mm, e.g. -Kukko 20/10-
♦ Extractor hooks, e.g. -Matra V/170-
♦ Interior extractor 46...58 mm, e.g. - Kukko 21/7-
♦ Countersupport, e.g. -Kukko 22/2 -
Note
♦ Before installing heat the inner ring of the tapered-roller bearing to 100°C.
♦ Replace both tapered-roller bearings together.
♦ When replacing the tapered-roller bearing of the differential housing, gearbox housing or converter housing adjust
the differential ⇒ Chap. 39-3.
S00.5318.02.20
1 - 22 Nm 29
T Coat screw head with seal- 15
ant -D 176 404 A2-
1
2 - Right flange shaft 28 2
T do not interchange, the left
and right flange shafts are of
different lengths
27 3
3 - Pressure spring for flange 4
shaft 26
5
4 - Thrust washer 25
T Fitting position: Collar to 24
pressure spring, leg to coni-
23 6 7 8 9 10
cal ring
5 - Conical ring 22
T with slots for thrust washer 21
catch 11
T Fitting position: Cone to- 12
wards differential housing
6 - Thrust washer 20
T for small differential bevel
gear
19 9 8 7 6
7 - Differential bevel gear small 18
page 10 5
8 - Thrust washer 4
T for large differential bevel 14
gear
3
9 - Differential bevel gear large 16 13
page 10 1
10 - Threaded part 15 S39-0164
11 - Tensioning sleeve
T to secure the axle for differential bevel gears
T use drift to drive in and drive out
12 - Axle for differential bevel gears
T do not damage thrust washers when driving in
13 - Flange shaft left
T do not interchange, the left and right flange shafts are of different lengths
14 - Fit pin
T for centering the gearbox housing and torque converter housing
15 - Gasket ring for flange shaft
T before installing moisten space between sealing lips with ATF
T can be replaced with the gearbox installed ⇒ Chap. 39-1
T remove with -MP 3-418-
T driving in ⇒ Chap. 39-1
T removing and installing ⇒ Chapter 39-1
T coat sealing surfaces with sealant -D176 404 A2- before assembling the gearbox housing and torque convert-
er housing
T press into the gearbox housing ⇒ Fig. 16 in 39-2 page 10
S00.5318.02.20
T press into the differential gear housing ⇒ Fig. 18 in 39-2 page 11
19 - 80 Nm
20 - Differential housing
21 - Pinion for final drive
T Number of teeth ⇒ Chap. 00-1
22 - Drive wheel for speedometer
T Insert the pegs of the drive gear in the slot of the differential gear housing, straight side facing outwards
T pressing on ⇒ Fig. 20 in 39-2 page 12
T installing ⇒ Fig. 22 in 39-2 page 12
T Determine thickness ⇒ Chapter 39-3
26 - Guide bush
T for speedometer drive
T only for vehicles without ABS; from 12.02
27 - Drive for speedometer
T only for vehicles without ABS; from 12.02
28 - Torque converter housing
T removing and installing ⇒ Chapter 39-2
T Removing and installing the oil pipe ⇒ Fig. 13 in 39-2 page 9
29 - 30 Nm
Fig. 13: Removing and installing the oil pipe -1- 1

– Release the fixing screws -arrows- of the clamps on
the oil pipe.
– Pull the oil pipe out of the torque converter housing.
– When installing press the oil pipe by hand up to the
stop of the torque converter housing.
– Tighten fixing screws -arrows- to 6 Nm.
N39-0460
S00.5318.02.20
Fig. 14: Install the differential bevel gears
– Oil the thrust washer for the small differential bevel

gears and insert on them.
– Insert the small differential bevel gears, drive in the
differential bevel axle.
– Drive in new tensioning sleeve.
– Oil the thrust washer for the large differential bevel
gears and insert on them.
– Fit the threaded part in the large differential bevel
gears.
– Insert and swivel the large differential bevel gears into
position with a 180° offset -arrow-.
N39-0461

A - Two-arm extractor, e. g. -Kukko 20/10- with extrac-
tion hook, e. g. -Matra V/170-
A
MP 3-431
S39-0169
MP 3-413
Fig. 16: Press inner ring/tapered-roller bearing into
the gearbox housing
MP 5-400
– Support the gearbox housing with a pressure pipe
-MP 6-408- directly below the bearing support.
MP 6-408
MP 3-420
MP 3-450
MP 3-407
S39-0172
S00.5318.02.20
Fig. 17: Pull off outer ring/tapered-roller bearing
A - Two-arm extractor, e. g. -Kukko 20/10- with extrac-
tion hook, e. g. -Matra V/170- A
– Insert extraction hooks in the recesses on the gearbox
housing.
MP 3-431
MP 3-467
S39-0173
Fig. 18: Press outer ring/tapered-roller bearing into

the differential gear housing
MP 3-408
T30036/3
MP 3-4071
S39-0174
– Fit thrust plate -MP 3-431- on the differential gear

housing.
V.A.G 1582
V.A.G 1582/3
N39-0466
S00.5318.02.20

ing
– Press inner ring/tapered-roller bearing onto the differ- MP 3-408

ential gear housing up to the stop.
MP 3-427
MP 3-407
S39-0175
Fig. 21: Pull off outer ring/tapered-roller bearing -C-

A - Interior extractor 46...58 mm, e.g. -Kukko 21/7-
B - Countersupport, e.g. -Kukko 22/2-
B
MP 3-457
A C
S39-0176
Fig. 22: Press in outer ring/tapered-roller bearing in

the torque converter housing MP 3-448
MP 3-464
MP 3-407
S39-0177
S00.5318.02.20
39-3 Adjusting the final drive
Overview of adjusting works

1 - Input gear
T is paired with the output 1 2
gear, replace together
2 - Drive pinion
3 - Tapered-roller bearing for in-
put shaft
T always replace together
T when replacing the tapered-
roller bearing determine the
adjusting washer again
4 - Adjusting washer for input
shaft
T Determine the thickness 3
⇒ 39-3 page 4
5 - Differential 3 4
6 - Adjusting washer for differen- 5
tial gear
T Determine the thickness
⇒ 39-3 page 2
7 - Tapered-roller bearing for dif-
8
ferential gear
T always replace together
T when replacing the tapered-
roller bearing determine the 7 6
adjusting washer again
7
8 - Output gear
T is paired with the drive gear,
replace together
N39-0499
Edition 07.00 Adjusting the final drive 39-3 page 1

S00.5318.00.20
Adjusting works when replacing individual components

When working on the gearbox it is only necessary to re-set the input shaft with output gear or differential gear housing
if parts were replaced that directly affect the settting of the final drive. To avoid unnecessary settings refer to the fol-
lowing table:
Set:
Differential Input shaft with output gear
component to be replaced: ⇒ 39-3 page 2 ⇒ 39-3 page 4
Gearbox housing X X
Torque converter housing X X
Output gear X
Drive pinion X
Tapered-roller bearing for input shaft X
Differential housing X
Tapered-roller bearing for differential gear X
Adjusting the differential gear

♦ Universal dial gauge holder -MP 3-447-
♦ Alignment rails -MP 3-457-
♦ Interior extractor 46...58 mm, e.g. -Kukko 21/7-
♦ Countersupport, e.g. -Kukko 22/2-
♦ Dial gauge
The differential gear must be re-set when

♦ Gearbox housing
♦ Torque converter housing
♦ Differential housing
or
♦ differential gear tapered-roller bearing
have been replaced.

Necessary adjusting work when replacing individual com-
ponents ⇒ 39-3 page 2.
Requirements
• Removing the planetary gear from the ATF pump
through to the large sun gear ⇒ Chap. 37-11
• Removing the input shaft ⇒ Chap. 37-11
39-3 page 2 Adjusting the final drive Edition 07.00

S00.5318.00.20
Setting
– Press outer ring/tapered-roller bearing without adjust- MP 3-448
ing washer into the torque converter housing.
– Insert the differential gear in the gearbox housing.
– Position the converter housing and tighten 8 screws to
torque 30 Nm.
MP 3-464
MP 3-407
S39-0177
– Set up the measuring device and dial gauge (3 mm

measuring range).
MP 3-447
– Insert the dial gauge with 1 mm bias and set on „0“.
– Move differential gear up and down.
– Read off play on dial gauge and note.
MP 3-405/17
Note
Do not turn the differential while measuring as otherwise
the bearings will settle and the measuring result will be in-
accurate.
Determining the adjusting washer

S39-0178
The prescribed bearing preload is reached by adding to
the established measured value a constant compression
value (0.16 mm).
Example:
Measured value 0.94 mm

+ compression (constant value) 0.16 mm
= Thickness of the adjusting washer 1.10 mm
– Unscrew the torque converter housing and remove

differential gear from gearbox housing.
– Remove outer ring/tapered-roller bearing -C- from
torque converter housing
A - Interior extractor 46...58 mm, e.g. -Kukko 21/7- B
B - Countersupport, e.g. -Kukko 22/2-
MP 3-457
– Determine the adjusting washers according to the ta-
ble ⇒ 39-3 page 4:
Spare part numbers ⇒ Spare Part Catalogue
A C
S39-0176

S00.5318.00.20
Adjusting washers (mm)

0,12 0,44 0,76
0,16 0,48 0,80
0,20 0,52 0,84
0,24 0,56 0,88
0,28 0,60 0,92
0,32 0,64 1,44
0,36 0,68
0,40 0,72
If the measured washer thickness is greater than the one

listed in the table, 2 washers corresponding to the meas-
ured value may be fitted.
– Press in outer ring/tapered-roller bearing with the de- MP 3-448

termined adjusting washers (in the example 1.10
mm).
Adjusting the input shaft

♦ Universal dial gauge holder -MP 3-447- MP 3-464
♦ Thrust piece -MP 3-423- MP 3-407
S39-0177
♦ Dial gauge extension -T30025/5-
♦ Dial gauge
The input shaft must be reset if

♦ Gearbox housing
♦ Torque converter housing
♦ Output gear
♦ Drive pinion
or
♦ Tapered-roller bearing of the input shaft
have been replaced.

Necessary adjusting work when replacing individual com-
ponents ⇒ 39-3 page 2.
Requirements
• Removing the planetary gear from the ATF pump
through to the large sun gear ⇒ Chap. 37-11
• Removing oil pan and slide valve body ⇒ Chap. 37-
11

S00.5318.00.20
Setting
– Press outer ring/tapered-roller bearing without adjust-
ing washer into the torque converter housing.
– Insert the input shaft in the gearbox housing. MP 3-456
– Position the converter housing and tighten 8 screws to
torque 30 Nm.
S39-0165
– Set up the measuring device and dial gauge (3 mm

measuring range).
– Set the dial gauge to „0“ with 1 mm bias.
A - Dial gauge extension (100 mm long) -T30025/5- MP 3-447
– Move input shaft up and down with a screwdriver on
the output gear. A
– Read off play on dial gauge and note (example: 1.02
mm).
Note
Do not turn the input shaft while measuring as otherwise
the bearings will settle and the measuring result will be in-
accurate. MP 3-405/17 S39-0179
Determining the adjusting washer

The prescribed bearing preload is reached by adding to
the established measured value a constant compression
value (0,18 mm).
Example:
Measured value 1.02 mm

+ compression (constant value) 0.18 mm
= Thickness of the adjusting washer 1.20 mm
– Determine the adjusting washers according to the ta-

ble ⇒ 39-3 page 6:
Spare part numbers ⇒ Spare Part Catalogue

S00.5318.00.20
Adjusting washers (mm)

0,10 0,44 0,72
0,20 0,48 0,76
0,24 0,52 0,80
0,28 0,56 0,84
0,32 0,60 0,88
0,36 0,64 0,94
0,40 0,68
If the measured washer thickness is greater than the one

listed in the table, 2 washers corresponding to the meas-
ured value may be fitted.

S00.5318.00.20

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 04.05 List of Supplements

List of Supplements Edition 04.05

01 – Self-diagnosis, Electrical Test

Edition 04.05 Table of Contents I

- Before fault finding .................................................................................... 37-3 page 1

Table of Contents Edition 04.05

39 – Final drive, differential

Edition 04.05 Table of Contents III

Table of Contents Edition 04.05

00-1 Technical Data for the

Identification of the gearbox

Location on the gearbox

– The gearbox identification characters also appear on

Edition 04.05 Technical Data for the Gearbox 00-1 page 1

Identification characters, aggregate assignment, ratios, capacities

Automatic gearbox 001

Planetary gear and final drive

Contents Automatic Gearbox 001

00-1 page 2 Technical Data for the Gearbox Edition 04.05

00-2 Information and repair In-

Information on the Automatic Gearbox

Automatic Gearbox Control Unit -J217-

O-rings, gasket rings, gaskets

Slide valve body

♦ After fitting it must be possible to turn the piston by

– If this defect occurs remove the piston.

♦ Do not forcefully over-extend brake band -B2-.

ATF (Automatic Transmission Fluid)

Gearbox speed sender -G38-

Vehicle speed sender -G68-

Gearbox oil temperature sender -G93-

Selector lever lock solenoid -N110-

Multi-function switch -F125-

Emergency running mode

Slide valve body

Automatic Gearbox Control Unit -J217-

LC (torque converter lockup clutch)

01 – Self-diagnosis, Electrical Test

01-1 Function of Self-diagno-

Additionally required information means

Control unit -J217 with driving situation circuits

Functions of gearbox control unit

Fault recognition of the gearbox control unit

Edition 07.00 Function of Self-diagnosis 01-1 page 1

During fault interrogation sporadic faults are displayed

Safety function of the gearbox control unit

Faults that may result in emergency running

Vehicle system tester -V.A.G 1552-

01-1 page 2 Function of Self-diagnosis Edition 07.00

Final control diagnosis no

Edition 07.00 Function of Self-diagnosis 01-1 page 3

01-1 page 4 Function of Self-diagnosis Edition 07.00

01-2 Electric/Electronic Components and Fitting Locations

1 - Engine control unit

Edition 07.00 Electric/Electronic Components and Fitting Locations 01-2 page 1

Fig. 2: Diagnostic connection

Fig. 3: Accelerator pedal position sender -G79-

01-2 page 2 Electric/Electronic Components and Fitting Locations Edition 07.00

Fig. 5: Relay for starter interlock switch -J207-

– Remove the storage area on the driver's side ⇒ Body 2