VW Transmission Disassembling and Assembling (Overhaul Procedure 096)

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Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-53



Transmission, disassembling
and assembling



ATF cooler and ATF filler tube, removing and
installing
page 37-54


Planetary gearbox disassembly and assembly,
overview
page 37-55


Planetary gearbox, disassembling page 37-70



Planetary gearbox, assembling page 37-76


Planetary gearbox adjustments, overview
page 37-89


Valve body, removing and installing page 38-
36

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-54

ATF cooler and ATF filler tube, removing
and installing
1 - Banjo bolt
Tightening torque: 35 Nm (26 ft lb)
2 - O-ring
Always replace
3 - ATF cooler
4 - O-ring
Always replace
5 - Transmission housing
6 - ATF dipstick
Checking ATF level page 37-47
7 - ATF filler tube
8 - Bolt
9 - O-ring
Always replace

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-55

Planetary gearbox disassembly and
assembly, overview
Note:
Disassembling planetary gearbox page 37-70 .
Assembling
page 37-76 .
I - ATF pump to support tube, removing
and installing page 37-57
II - Reverse gear clutch -K2- to large sun
gear, removing and installing page
37-61
Note:
The small sun wheel (arrow 1) cannot be removed
from the planet carrier in transmissions from 01.93
page 00-5 .

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-56


III - Free wheel and reverse gear brake -B1-
, removing and installing page 37-64
Note:
To remove and install free wheel first remove valve
body together with plugs page 38-36 .
IV - Planet carrier and input gear, removing
and installing page 37-67
Note:
It is not necessary to remove the input gear
(arrow).
Removing and installing input gear page
39-8 .


Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-57

I - ATF pump to support tube, removing
and installing
Overview, page 37-55
Note:
Disassembling planetary gearbox page 37-70 .
Assembling
page 37-76 .
1 - Bolt
Qty. 7
Tightening torque: 8 Nm (71 in lb) plus an
additional 1/4 -turn (90 )
The additional 1/4 -turn (90 ) may be done
in several stages
2 - ATF pump with -B2- piston
Disassembling and assembling page 38-
1
3 - O-ring
Always replace
Place on ATF pump

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-58


4 - Gasket
Always replace
5 - Spring cap
Qty. 6
Install 3 spring caps after installing first
outer plate
Install 3 spring caps before installing last
outer plate
6 - Spring
Qty. 3
7 - Corrugated spring washer
8 - Outer plate -B2-
Quantity
from page 00-3
Determining thickness of outer plate
page 37-113 , 2nd and 4th gear brake -B2-,
adjusting

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-59


9 - Inner plate -B2-
Quantity
from page 00-3
Before installing, place in in ATF for 15
minutes
10 - Outer plate -B2-
Always install outer plates that are 2 mm
(0.079 in.) thick
Quantity
from page 00-3
11 - Outer plate -B2-
Fit 3 mm (0.118 in.) thick outer plate to
supporting tube

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-60


12 - Supporting tube -B2-
For -B2- plate package
Length of -B2-:
with 4 inner plates 72.3 mm
(2.846 in.)
with 5 inner plates 68.6 mm
(2.701 in.)
with 6 inner plates 64.9 mm
(2.555 in.)
Quantity of -B2- inner plates from page 00-3
Insert so that groove engages in wedge of free
wheel

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-61

II - Reverse gear clutch -K2- to large sun
gear, removing and installing
Overview, page 37-55
Note:
Disassembling planetary gearbox page 37-70 .
Assembling
page 37-76 .
1 - Reverse gear clutch -K2-
Disassembling and assembling page 38-
23
2 - Shim
Determining thickness page 37-106 ,
Clutch play between -K1- and -K2-,
adjusting
1 or 2 shims can be installed
3 - 1st to 3rd gear clutch -K1- with turbine
shaft
With ball valve (arrow), disassembling and
assembling
page 38-16
Without ball valve (for transmissions from
01.93
page 00-5 ). Disassembling and
assembling
page 38-16

Volkswagen Golf, GTI, Jetta 93-99, Cabrio 95 - 4 Spd. Automatic Transmission 096
37-62


4 - Axial needle bearing washer
5 - Axial needle bearing
6 - Axial needle bearing washer
Lugs face toward axial needle bearing
7 - 4th gear clutch -K3- with pump shaft
With ball valve (arrow), disassembling and
assembling
page 38-26
4th gear clutch -K3- without ball valve (for
transmissions from 01.93 page 00-5 ),
disassembling and assembling page 38-
26 .
8 - Axial needle bearing with washer
Axial needle bearing faces toward small
drive shaft
9 - Small drive shaft
10 - Needle bearing
11 - Axial needle bearing