Service

Workshop Manual
Passat 1997 ➤
4-speed automatic gearbox 01N
Edition 10.2005

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Service Department. Technical Information

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List of Workshop Manual Repair Groups

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00 - Technical data utho tee
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38 - Gears, control

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg K0050605920

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Suggestions and criticism of this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Further information on “automatic gearbox 01N” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Self-Study Programme on CD ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Design and function of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.3 Historical development oflkthis en AG. V
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3 Gearbox identification d b . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4 Identification codes, ho engine allocation, ratios, equipment . . .e o. r .a . . . . . . . . . . . . . . . . . . . . . 7
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5 Capacities .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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5.1 Planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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5.2 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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6 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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6.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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6.3 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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6.4 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.6 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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6.7 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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6.8 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.9 Inner plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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6.10 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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6.11 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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6.12 Valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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6.13 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi

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6.14 Guided fault finding, vehicle self-diagnosis and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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7 Repair with an exchange component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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7.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.3 Contents of an exchange component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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7.4 Components of -B1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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7.5 Components of -B2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.6 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.7 Valve body with ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 Fault finding for the automatic 4-speed gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1 Vehicle cannot drive forwards or backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2 Vehicle will not drive forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3 Vehicle will not reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.4 Gearbox oily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.5 Oil or ATF leaks around torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.6 Visible fouling of ATF and/or engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.7 ATF level too low, final drive oil level too high (or vice versa) - no external leaks in gearbox
........................................................................ 26
8.8 Gearbox oily only near breather - no other external leaks in gearbox . . . . . . . . . . . . . . . . 26
8.9 ATF escaping from breather (only for longitudinally installed gearbox 01N) . . . . . . . . . . . . 26
8.10 Selector mechanism does not move freely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.11 Not all selector lever positions can be selected; selected drive ranges do not function . . . . 27
8.12 Parking lock does not engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.13 Parking lock disengages “with a jolt” (selector lever sometimes difficult to move from “P” to
“R”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.14 Final drive noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.15 Performance - jolting in neutral or during certain engine and gearbox movements . . . . . . 28

Contents i
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.16 Engine speed drops when driving range is selected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.17 Vehicle does not start or also starts in “R-D-3-2-1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.18 Vehicle does not start or engine stalls after a short time . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.19 Selector lever can be moved from “N” or “P” without brake being operated . . . . . . . . . . . . 29
8.20 Selector lever cannot be moved from “N” or “P” although brake is operated . . . . . . . . . . . . 29
8.21 Shifts occur sporadically or not at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.22 All shifts are “hard or jolting” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.23 One particular shift is “hard or jolting” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.24 Shift from 3rd to 4th gear takes “too long” in vehicles through 12.92 having economy/sport
switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.25 Shifts take “too long” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.26 Hard shifts immediately after repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.27 Gearbox downshifts at constant vehicle speed without apparent reason . . . . . . . . . . . . . . 32
8.28 Gearbox does not downshift for kickdown ...................................... 32
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8.30 Gearbox switches to d bemergency running . . . . . . . . . .gu. a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . 33
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8.31 Selector lever uposition
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“1”, gearbox does not shift to 1st gear e(no
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gear) . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . .
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8.32 Selector lever position “D”, “3” or “2”, gearbox does not shift to 1st gear (no power

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8.33 Selector lever position “D”, “3” or “2”, automatic gearbox does not shift to 2nd gear (no power
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8.34 Selector lever position “D” or “3” does not shift to 3rd gear, hydraulic (3H) . . . . . . . . . . . . 34

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8.35 Selector lever position “D” or “3” does not shift to 3rd gear, mechanical (3M) . . . . . . . . . . 35
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8.36 Selector lever position “D” or “3” does not shift to 3rd gear (not gearbox 001) . . . . . . . . . . 35
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8.37 Selector lever position “D” does not shift to 4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.38 Selector lever position “D” does not shift to 4th gear, mechanical (4M) . . . . . . . . . . . . . . . . 36
8.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear . . . . . . . . . . 36
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.2 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.3 Allocation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.4 Removing sleeve bearing from turbine shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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1.5 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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1.6 Removing and installing torque converter seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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1.7 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.8 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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1 Connecting Volkswagen tester and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Carry out basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Checking operation of the ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4 Dismantling and assembling shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.5 Removing and installing selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.6 Dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.7 Removing and installing pull rod upper part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.8 Removing and installing selector lever lock solenoid N110 and wiring for selector lever
illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.9 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.10 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4.11 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.12 Removing, installing and adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5 Measuring main pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.3 Transporting automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.4 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.5 Removing and installing left and right gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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8 Gearbox with selector elements s. w. a.g.en. A. G . .. . . . . . g.e.n.A.G.d.oe. s. . . . . . . . . . . . . . . . . . . . . . . . . . 105
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9 Dismantling and assembling yV
bgearbox . . . . . . . . . . . . . . . . . . g.ua. ra. . . . . . . . . . . . . . . . . . . . 107
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9.1 Removing and installingthoATF lines . . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . .
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9.2 Cleaning ATF lines and
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ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . 111

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9.3 Overview - dismantling and assembling planetary gearbox . . . . . . . . . . . . . . . . . . . . . . . .
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9.4 I - Removing and installing ATF pump to support tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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9.5 II - Removing and installing reverse clutch -K2- to large sun gear . . . . . . . . . . . . . . . . . . . . 114

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9.6 III - Removing and installing freewheel and reverse gear brake -B1- . . . . . . . . . . . . . . . . 115
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9.7 IV - Planet carrier and gearbox housing with input gear and cover . . . . . . . . . . . . . . . . . . 116

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9.8 Dismantling planetary gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

spec
es, in part or in w

9.9 Assembling planetary gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

t to the co
9.10 Installing exchange component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.11 Overview - all planetary gearbox adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

rrectness of i
9.12 Adjusting planet carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.13 Adjusting reverse gear brake -B1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
l purpos

9.14 Adjusting clutch play between -K1- and -K2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

9.15 Adjusting 2nd and 4th gear brake -B2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

nform
ercia

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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1 Dismantling and assembling ATF pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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2 Dismantling and assembling freewheel with -B1- piston . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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3 Dismantling and assembling 1st to 3rd gear clutch -K1- . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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4 Dismantling and assembling reverse gear clutch -K2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft . . . . . . . . . . . . 175
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6 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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7 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.2 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9 Removing and installing gearbox oil temperature sender G93 . . . . . . . . . . . . . . . . . . . . . . 190
10 Dismantling and assembling parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
11 Renewing speedometer sender G22 or driving speed sender G68 . . . . . . . . . . . . . . . . . . 197

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

1 Checking gear oil in final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 Renewing oil seal for left or right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.2 Renewing right drive flange oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.3 Removing and installing deep groove ball bearing for output shaft of drive flange . . . . . . 204
3 Dismantling and assembling final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Contents iii
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3.1 Overview - final drive repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

3.2 Removing and installing input gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.3 Removing and installing pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.4 Removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.5 Assembly overview - dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . 222
3.6 Dismantling and assembling differential (procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4 Adjusting final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.1 Overview of adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.2 Adjustments to be completed after renewing individual components . . . . . . . . . . . . . . . . . . 229
4.3 Adjusting input gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.2 Adjustment and marking of final drive gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.3 Recommended sequence for new adjustment of final drive gear set . . . . . . . . . . . . . . . . . . 234
5.4 Adjusting pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5.5 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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iv Contents
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

00 – Technical data
1 Suggestions and criticism of this workshop manual

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This workshop manual was made for you. It should support you
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and be an aid to you. If you use ⇒ ELSA, you can send us sug‐
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gestions, “praise and criticism” from anywhere in the world.

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One example of a reader's suggestion which has been “imple‐

mented” is the chapter “Definitions” in the workshop manual ⇒
Automatic gearbox 001; Rep. Gr. 39 ; Final drive, differential;
Adjusting final drive; Definitions for the Polo 2002.
– “Click” into it once! Have a look.

1. Suggestions and criticism of this workshop manual 1

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

If you find this chapter useful, or would like such a chapter in this
workshop manual or have additional suggestion, gen AG write to us.
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2 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

2 Further information on “automatic

gearbox 01N”

2.1 Self-Study Programme on ⇒ CD ROM

You can gain further information from the ⇒ CD ROM ⇒ Multi-
media training; Power transmission 1-4 .
Order number:
♦ Part 1: 000.2600.20.XX*
♦ Part 2: 000.26000.21.XX*
♦ Part 3: 000.26000.23.XX*
♦ Part 4: 000.26000.22.XX*
♦ XX* = Language code for British English = 20

2.2 Design and function of gearbox

For more information about the function of the 4-speed automatic
gearbox, see ⇒ Self-study programme No. 112 ; electrohydraul‐
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1988
Volkswagen introduces the electronically controlled 4-speed
gearbox to phase out the hydraulically controlled 3-speed gear‐
rrectness of i

box that had been installed up till then. For the first time, the
l purpos

passenger car version “096” is installed in the Passat and other

models follow. The gearbox for inline engines is “097”, for the
Sharan the “099” and for the Transporter the “098” gearbox.
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1993
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In January 1993, the first phase of modifications begins that are

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also visible on the “outside” of the gearbox:

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♦ The mechanical programme switch, first as a one-touch

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switch, then as a dial switch, is dispensed with. New software,

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♦ Increased in-gear acceleration and improved shift comfort are
achieved by modifying the shift logic and the clutches. The
“mechanical 3rd gear”, that previously could only be engaged
by means of the load splitters “LT1” and “LT2”, is dispensed
with and replaced by a purely hydraulic gear.
♦ A “novel” multi-function switch (Hall sender principle) is intro‐
duced. This also entails modifications to the cabling of the
vehicle wiring harness to the gearbox.
♦ Now, the software is even able to detect whether the vehicle
is driving on the flat or over hilly terrain. Additional gear change

2. Further information on “automatic gearbox 01N” 3

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

maps automatically select gear changes for gradients de‐

pendent upon accelerator pedal position and road resistance.
One gear change map is adapted to the engine output when
climbing steep hills, while a different gear change map is
specified for descending steep hills and the braking effort of
the engine.
♦ The clutches now work with oil on both sides of the piston,
meaning they are “centrifugally balanced”.
1995
In a second phase, the automatic gearbox “01P” is developed
from gearbox 097. Numerous modifications are adopted once
again, the most important being:

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♦ Switch to synthetic oil in both oil circuits. The ⇒ ATF dipstick

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♦ The torque converter is equipped with a lock-up clutch.

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♦ The gearbox speed counter -G38- is used for the first time.
♦ Here in the “transverse version”.
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♦ Here in the “inline version”.

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♦ Volkswagen is the world's first gearbox manufacturer to use ⇒

fuzzy logic.
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The efficiency of the gearbox is optimised. The goal was to reduce

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the “internal resistance” of the gearbox in order to achieve fuel

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4 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Installation of low-friction bearings on rotating parts such as

the pinion shaft, input and output gears and differential.
♦ To a certain extent, this enables the bearing tension to be re‐
duced, although these bearings can no longer be dynamically
measured. Low-friction bearings can only be set using geo‐
metrical measurement.
♦ The groove pattern in the clutch friction discs is changed.
♦ Brake “B2” receives a retaining ring with shim -B- in place of
corrugated washer -A-. This enables the brake to be closed
with greater control than before.

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2. Further information on “automatic gearbox 01N” 5

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3 Gearbox identification
The “4-speed automatic gearbox 01N” is installed in the Passat
1997 ▸ in conjunction with 4-cylinder engines. Allocation
⇒ page 7 .
Codes -arrow 1-.
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Identification Day Month Year 1996 of manufac‐
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The gearbox code also appears on the vehicle identification
plates.

6 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4 Identification codes, engine allocation, ratios, equipment

Automatic gearbox 01N
Gearbox Identification code DFG DFH DFK
Manufactured from 12.95 12.95 02.96
to 12.96 12.96 12.96
⇒ Torque converter Identification code
for turbine shaft with sleeve bearing bush LADC LCDC LCDC
⇒ page 38
for turbine shaft without sleeve bearing bush LADD LCDD LCDD
⇒ page 38
⇒ Valve body Identification code LCA LCA LCA
Number of plates Inner Outer Inner Outer Inner Outer
Clutch -K1- 5 5 5 5 5 5
Clutch -K2- 5 5 5 5 5 5
Clutch -K3- 5 4 6 5 6 5
⇒ Brake -B1- 5 5 5 5 6 6
⇒ Brake -B2- 6 7 6 7 6 7
Allocation Model Passat 1997 ▸ Passat 1997 ▸ Passat 1997 ▸
Engine 1.6 l - 74 kW 1.9enl ATDI
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1.8 l - 92 kW olkswag does
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Ratios 1st gear 2.714rise
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2nd gear s
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1.441 1.441 or ac
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3rd gear 1.000 1.000 1.000

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4th gear 0.679 0.742 0.742

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Reverse gear 2.111 2.884 2.884

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Intermediate drive No. of teeth Input 44 44 44

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Output 51 51 51
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Gears 1.159 1.159 1.159
Final drive No. of teeth Pinion 9 11 13

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Crown 40 35 38
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Gear ratios 4.444 3.182 2.923 nf
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Drive shaft Flange ∅ mm 108 108 108
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Gearbox Identification code DMU DMV DMX

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for turbine shaft with sleeve bearing bush LADC LCEC LCEC
⇒ page 38
for turbine shaft without sleeve bearing bush LADD LCED LCED
⇒ page 38
⇒ Valve body Identification code LFA LFA LFA
Number of plates Inner Outer Inner Outer Inner Outer
Clutch -K1- 5 5 5 5 5 5

4. Identification codes, engine allocation, ratios, equipment 7

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Automatic gearbox 01N

Gearbox Identification code DMU DMV DMX
Clutch -K2- 4 4 5 5 5 5
Clutch -K3- 5 4 6 5 6 5
⇒ Brake -B1- 5 5 5 5 6 6
⇒ Brake -B2- 4 5 5 6 5 6
Allocation Model Passat 1997 ▸ Passat 1997 ▸ Passat 1997 ▸
Engine 1.6 l - 74 kW 1.9 l TDI - 66 kW 1.9 l TDI - 81 kW
1.8 l - 92 kW
2.0 l - 85 kW
2.0 l - 88 kW
Ratios 1st gear 2.714 2.714 2.714
2nd gear 1.551 1.441 1.441
3rd gear 1.000 1.000 1.000
4th gear wage n AG0.679
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Intermediate drive No. of teeth uth Input
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Output 51 51 51
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Gears 1.159 1.159 1.159

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Final drive No. of teeth Pinion 9 11 13

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shaft

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Crown 40 35 38
es, in part or in w

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Gears 4.444 3.182 2.923
Drive shaft Flange ∅ mm 130 130 130

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Automatic gearbox 01N

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Gearbox Identification code EPT EPU EPV

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⇒ Valve body Identification code LFA LFA LFA

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Number of plates Inner Outer Inner Outer Inner Outer

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Clutch -K1- 5 5 5 5 5 5
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Clutch -K3- 5 4 6 5 6 5
⇒ Brake -B1- 5 5 5 5 6 6
⇒ Brake -B2- 4 5 5 6 5 6
Allocation Model Passat 1997 ▸ Passat 1997 ▸ Passat 1997 ▸
Engine 1.6 l - 74 kW 1.9 l TDI -66 kW 1.9 l TDI - 74 kW
1.6 l - 75 kW 1.9 l TDI - 81 kW
1.8 l - 92 kW
2.0 l - 85 kW
2.0 l - 88 kW
Ratios 1st gear 2.714 2.714 2.714
2nd gear 1.551 1.441 1.441
3rd gear 1.000 1.000 1.000
4th gear 0.679 0.742 0.742

8 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Automatic gearbox 01N

Gearbox Identification code EPT EPU EPV
Reverse gear 2.111 2.884 2.884
Intermediate drive No. of teeth Input 44 44 44
gear
Output 51 51 51
gear
Gears 1.159 1.159 1.159
Final drive No. of teeth Pinion 9 11 13
shaft
Crown 40 35 38
wheel
Gears 4.444 3.180 2.920
Drive shaft Flange ∅ mm 130 130 130

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Identification codes, engine allocation, ratios, equipment 9

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
5 Capacities thoris nte
eo
au ra
c
ss

ce
le
un

pt
5.1 Planetary gear

an
d
itte

y li
erm

ab
ility
Capacities ⇒ Planetary gear Automatic
ot p

wit
is n gearbox

h re
ole,

Initial filling 5.75 l 01N

spec
urposes, in part or in wh

Lubricant VW ⇒ ATF

t to the co
VW ⇒ ATF is available as a part.

rrectne
Container size 0.5 l - part number -G 052 162 A1-
Container size 1.0 l - part number -G 052 162 A2-

ss o
5.2 Final drive
cial p

f inform
mer

Capacities Final drive Auto. Gearbox

atio
om

n
Initial filling 1.0 l 01N
c

i
or

n thi
e

Lubricant Gear oil SAE75 W90

t

sd
va

(synthetic oil)
i

o
pr

cum
r
fo

en
ng

Gear oil SAE 75 W90 (synthetic oil) is available as a part.

t.
yi Co
Cop py
Container size 0.5 l - part number -G 052 145 A1-
t. rig
gh ht
pyri by
Vo
o
by c
Container size 1.0 l - part number -G 052 145 A2-
lksw
cted agen
Prote AG.
Checking gear oil in front final drive ⇒ page 198 .

10 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6 Repair instructions
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of generally valid instructions applicable for the various
repair procedures - which were formerly repeated a number of
times at numerous places in the workshop manual - are summar‐
ised here. They apply to this workshop manual.
– Have a look at the next chapter in this document. There is sure
to be something interesting for you there.

6.1 Tools
A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
The catalogue can be ordered the usual way from Bertelsmann
also as a CD ROM and is also available in the ServiceNet.
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with
these bolts.

6.2 Gearbox
n AG. Volkswagen AG do
wage es n
♦ If gearbox covers have been unbolted or gearbox has no fluid,
Vol
ks ot g
by ua
do not run engine or tow vehicle. ise
d ran
tee
r
tho
♦ First thoroughly clean connecting points and surrounding
au
or
ac
areas and then loosen bolts. ss
ce
le
un

pt

♦ When installing the gearbox, ensure that dowel sleeves be‐

an
d
itte

y li

tween the engine and gearbox are correctly located.

erm

ab
ility
ot p

♦ Place removed parts on a clean surface. Cover parts to pre‐

wit
is n

vent soiling. Use plastic sheeting and paper. Use lint-free

h re

cloths only!
ole,

spec
urposes, in part or in wh

♦ Install only clean parts; do not remove new parts from pack‐
t to the co

aging until immediately before installing.

♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
rrectne

♦ With gearbox removed, secure torque converter against falling

s

out.
s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

11
cop Vo
by lksw
Prote
cted AG. 6. Repair instructions
agen
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Gearboxes with and without filler pipe

Here is an “example” with a filler pipe as it is installed in “older”
gearboxes. This pipe has been discontinued.

This “old” filler opening with the red cap is also not needed be‐
cause ⇒ ATF can be drained or filled through the bottom hole as
required. The “height” of this tube determines the level of the ⇒
ATF.
The tube must be removed to drain the fluid.
♦ After installation, check the ⇒ ATF level and top up
⇒ page 100 .
♦ Capacities and specifications ⇒ page 10 . agen
AG. Volkswagen AG d
oes
olksw not
⇒ Exchange component d by
V gu
ara
ise nte
or eo
h
aut ra
ss c

ce
e

There is an ⇒ exchange component available for gearbox repairs

nl

pt
du

an
which is often more economical than an exchange gearbox or a
itte

y li
complete rebuild.
erm

ab
ility
ot p

More information about repairs with this exchange component is

wit
, is n

available here ⇒ page 17 .

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

♦ This ⇒ exchange component contains all selector elements

n

t.
yi Co
and the valve body. It is allocated to the gearbox according to Cop py
t. rig
its code letter and can be ordered from the ⇒ Electronic parts yri
gh by
ht
catalogue “ETKA” .
op Vo
by c lksw
cted agen
Prote
♦ For more information about what an ⇒ exchange component
AG.

is and what advantages it offers over a “complete repair”, refer

to ⇒ page 17 .

12 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.3 ⇒ ATF
Automatic Transmission Fluid

Caution

Be careful when working with ⇒ ATF. Dispose of drained ⇒ ATF

according to regulations. Remember: one drop of ATF will con‐
taminate 1,000 litres of water.

The ⇒ ATF does more than just “lubricate” the gearbox.

Consider that the ATF which just transported miniscule particles
of metal to the filter and ensured that the film of lubricant on the
flanks of the teeth does not tear now provides the pressure nec‐
essary for the shift valves to do their job.
In addition, it seals the spool valves and aids the friction plates in
the clutch during gear changes. It stores and transports heat and
reduces noise - the ⇒ ATF performs many tasks. And it doesn't
matter for the ATF if this happens on the hot equator or at a frigid
pole of the earth. The ⇒ ATF fulfils very high demands!
⇒ ATF and fault finding via ⇒ ATF check

You have just read about all the things that ⇒ ATF does. There is
just one thing it cannot do: “disappear without a trace”.
n AG. Volkswagen AG age does
ksw n
⇒ ATF can only go missing
by if it has run out of the gearbox.gua
Vol ot
d ran
ise
– Therefore, check ho where the ATF has escaped from the gear‐e o
r te
ut
box. First repair
ss
a this leak. ra
c
ce
le

The ⇒ ATF is obtainable as a spare part. Therefore the part num‐

un

pt
an
d

ber for it can also be found in the ⇒ Electronic parts catalogue

itte

y li

“ETKA” .
rm

ab
pe

ility

Do not mix any additives into the ⇒ ATF or use a substitute ⇒ ATF.
ot

wit
, is n

h re

⇒ ATF which has been drained out cannot be filled again.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

6.4 Seals and sealing rings

m

a
com

ti

♦ Always renew O-rings, seals and gaskets.

on in
r
te o

thi

♦ Before installing a radial shaft seal, coat sealing lips and area
s
iva

between these with sealing grease -G 052 128- and outer cir‐
do
r
rp

cumference with ⇒ ATF.

um
fo

en
ng

t.
yi
♦ Open side of oil seal faces oil.
Co
Cop py
ht. rig
♦ After installing, check ⇒ ATF level in planetary gearbox or gear rig ht
py by
Vo
oil in final drive and correct level if necessary.
co lksw
by
cted agen
Prote AG.

6. Repair instructions 13
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.5 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant particularly sensitive parts, e.g. the valve body,
and loosen or tighten diagonally in stages.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush. Then insert bolts with locking fluid -
AMV 185 100 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Always renew self-locking bolts and nuts.
♦ Always renew bolts that have to be turned further through a
particular angle after tightening.

6.6 Locking devices

♦ Do not overstretch retaining rings. Renew as necessary.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
AG. Volkswagen AG d
of force. ksw
agen oes
n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
6.7 Bearings
hole

spec
es, in part or in w

♦ Tapered roller bearings are allocated according to gearbox

date of manufacture and gearbox code in the Parts Catalogue. t to the co

♦ All tapered roller bearings fitted to the same shaft must be re‐
rrectness of i

newed as a set. Use same make of bearings.

l purpos

♦ Install needle bearings with lettered side (thicker metal) to‐

wards fitting tool.
nf
ercia

♦ Heat taper roller bearing inner races to approx. 100 ±C before

or

installing.
m
m

atio
m

♦ Do not interchange outer or inner races of bearings of the

o

n in
or c

same size. The bearings are matched in pairs.

thi
te

sd
iva

6.8 Piston rings

o
r
rp

cu
o

m
f

en
ng

t.
♦ Do not over-stretch when removing and installing. Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

14 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.9 Inner plates

♦ Lay new inner plates in ⇒ ATF fluid for
n15
AG.minutes
Volkswagebefore
n AG d in‐
stalling. wage oes
olks no t gu
yV
db ara
rise nte
tho eo
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
6.10 Shims

rrectness of i
♦ Measure shims at several points with a micrometer. Various
tolerances make it possible to obtain the exact shim thickness
l purpos

required.
♦ Check for burrs and damage.

nf
ercia

or
♦ Install only flawless shims.

m
m

atio
om

6.11 Clutches

n in
or c

thi
te

sd
a

♦ Clutches can be dismantled for cleaning and inspection, and

iv

o
r
rp

defective parts (e.g. outer or inner plates) can be allocated

cu
o

m
f

according to gearbox code.

en
ng

t.
yi Co
op
♦ Before installing a piston, moisten sealing lips and seals with
C py
t. rig
gh
⇒ ATF.
ht
pyri by
Vo
o
by c lksw
cted
6.12 Valve body
agen
Prote AG.

♦ If selector elements are burnt, the valve body and ⇒ ATF

strainer must be renewed. Often, it is worthwhile installing an
⇒ exchange component.
♦ Allocate valve body according to gearbox code ⇒ Electronic
parts catalogue “ETKA” .

6.13 Electrical components

You have probably at some time received an electrical shock
when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.
– Before beginning work on electrical components, touch an
earthed object, for example a water pipe or lifting platform.
Please do not touch connectors directly.

6. Repair instructions 15
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.14 Guided fault finding, vehicle ⇒ self-diag‐

nosis and testing
Before making repairs to the gearbox, determine the cause of the
fault as precisely as possible with the aid of guided fault find-
ing .

– To do this, connect one of the Volkswagen testers

⇒ page 43 .
First see if guided fault finding can “help” ⇒ page 24 .
The guided functions will guide you to the ⇒ ATF temperature
in the shortest way possible ⇒ page 43 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

16 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

7 Repair with an exchange component

7.1 General information

7.1.1 What is an ⇒ exchange component?

The ⇒ exchange component -arrow- is an economical set of parts.
It contains all the ⇒ clutches, all the ⇒ brakes, the ⇒ ATF pump,
the ⇒ planetary gear set and the ⇒ valve body of the respective
gearbox.
For a description of the ⇒ exchange component and the meas‐
uring procedure for adjusting clutch play when installing, please
also refer to VW/Audi TV programme No. 42; API Technology
Direct dated 28.02.1998.
You can order this shipment by phoning the hotline ++49 5423 94
34 44 and quoting order no. 042.5124.67.01.
The parts included in the ⇒ exchange component are described agen AG. Volkswagen AG do
here ⇒ page 17 . Vol
ksw es n
ot g
by ua
ed ran
The following are not included: O-rings for ⇒ ATF cooler ho
rand
is ⇒ tee
ATF filler pipe, multi-function switch -F125- , gearbox speed
aut send‐ or
ac
er -G68- and gearbox speed sender -G38- . ss

ce
le
un

pt
These parts must be ordered additionally if they are required.

an
d
itte

y li
erm

ab
Gaskets for the pan and the intermediate drive cover must also

ility
ot p

be ordered extra.

wit
is n

h re
If required, the conductor strip of the ⇒ valve body must also be
ole,

ordered extra.

spec
urposes, in part or in wh

t to the co
7.1.2 How can an ⇒ exchange component be
obtained?

rrectne
The ⇒ exchange component is allocated to a gearbox according
to the gearbox code and can, like every other Genuine part also

ss
be ordered from “Genuine Parts Division”.

o
cial p

f inform
7.2 Adjustments
mer

atio
m

Only the clutch play needs to be adjusted when an ⇒ exchange

o

n
c

i
or

n
component is installed.
thi
te

sd
va

How to do this is described in a procedure in this workshop man‐

i

o
pr

cum

ual.
r
fo

en
ng

t.
yi Co
Dismantling ⇒ planetary gearbox ⇒ page 118 . . Cop py
rig
ht ht
rig
Installing ⇒ exchange component ⇒ page 134 . py by
co Vo
by lksw
cted agen
7.3 Contents of an ⇒ exchange component
Prote AG.

7. Repair with an exchange component 17

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - ⇒ ATF pump with -B2- pis‐

ton
2 - Components of -B2-
❑ ⇒ page 19
3 - Reverse gear clutch -K2-
4 - Shims for clutch play
❑ Shims of various col‐
ours have various thick‐
nesses.
5 - 1st through 3rd gear clutch
-K1-
❑ ⇒ Clutches -K1- and -
K3- may be pressed to‐
gether.
6 - 3rd and 4th gear clutch -K3-
with turbine shaft
❑ ⇒ Clutches -K1- and -
K3- may be pressed to‐
gether.
7 - Needle thrust bearing with
washer
8 - Freewheel with -B1- piston n AG. Volkswagen AG do
swage es n
9 - Components of -B1- byV
olk ot g
ua
d ran
❑ ⇒ page 19 ir se tee
tho
u or
a ac
10 - ATF strainer ss

ce
e
nl

11 - Seal

pt
du

an
itte

y li
❑ Push onto intake neck of
erm

ab
strainer -arrow- by

ility
ot p

hand.

wit
, is n

h re
12 - ⇒ Valve body
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

18 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

7.4 Components of -B1-

1 - Retaining ring
❑ For support tube -B2-.
2 - Retaining ring
❑ For freewheel.
3 - Freewheel with -B1- piston
4 - Dished spring
5 - Pressure plate -B1-
6 - Inner plate -B1-
7 - Outer plate -B1-
AG. Volkswagen AG d
agen oes
8 - Shim olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
7.5 Components of -B2- Cop py
ht. rig
rig ht
py by
There are two versions of this ⇒ brake. co Vo
by lksw
cted agen
Prote
Version -A- with:
AG.

7. Repair with an exchange component 19

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Passat 1997 ➤ ir se
d ran
tee
o
4-speed automatic gearbox 01N -auEdition 10.2005
th or
ac
ss

ce
e
1 - Corrugated washer

nl

pt
du

an
itte

y li
2 - Outer plate -B2-

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

or
Version -B- with:

20 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3 - Retaining ring
4 - Shim
5 - Outer plate -B2-
❑ 3 mm thick.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
7.6 ⇒ Clutches
gh ht
pyri by
Vo
co lksw
by
cted agen
There are two versions of clutches -K1- and -K3-. Prote AG.

Version -A- with:

3+4+5 - ⇒ Clutches are pressed together. They do not need to be
pressed apart.
Version -B- with:

7. Repair with an exchange component 21

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

⇒ Clutches can pushed together loosely. AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
e
1 - Reverse gear clutch -K2- horis nte
eo
aut ra
2 - Shims for clutch play ss c

ce
e
nl
❑ Shims of various col‐

pt
du

an
ours have various thick‐

itte

y li
nesses.

erm

ab
ility
❑ Up to 3 shims can be in‐ ot p

wit
, is n
stalled.

h re
hole

spec
3 - 1st to 3rd gear clutch -K1-
es, in part or in w

t to the co
4 - O-ring
5 - 3rd and 4th gear clutch -K3-
with turbine shaft

rrectness of i
6 - Needle thrust bearing with
l purpos

washer

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

22 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

7.7 ⇒ Valve body with ATF strainer

1 - ATF strainer
2 - Seal AG. Volkswagen AG d
agen oes
olksw not
❑ Push onto intake neck of d by V gu
ara
strainer -arrow- by rise nte
ho eo
hand. aut ra
c
ss
3 - ⇒ Valve body

ce
le
un

pt
an
d
❑ The ⇒ valve body in the

itte

y li
⇒ exchange component

rm

ab
pe
is always without con‐

ility
ot
ductor strip.

wit
, is n

h re
❑ The conductor strip
hole

spec
must be ordered sepa‐
es, in part or in w
rately if necessary.

t to the co
4 - Freewheel plug
❑ The plug must be or‐

rrectness of i
dered separately if nec‐
essary.
l purpos

5 - O-ring

nform
ercia

6 - O-ring
m

a
com

t
7 - Operating rod for spool

ion in
valve
r
te o

thi
❑ With steel spring and

s
iva

do
bolt.
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7. Repair with an exchange component 23

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8 Fault finding for the automatic 4-

speed gearbox
Fault finding contains a number of malfunction tables based on
the most common complaints which indicate possible sources of
the trouble.
To evaluate a complaint, it is necessary to have as complete in‐
formation about the malfunction and the development of the
problem as possible. The symptoms described by the customer
should be checked during a road test “with the customer driving”.
Knowledge of the construction and function of the gearbox is es‐
sential for an accurate diagnosis ⇒ page 3 .
To avoid further damage or misdiagnoses, the following points
must be checked and, as necessary, corrected “before” the road
test.
♦ External damage, such as leaks
♦ Basic setting was performed ⇒ page 45
♦ Selector lever cable is correctly adjusted ⇒ page 68
♦ ⇒ ATF level is correct; ⇒ ATF does not smell burnt and is free
of foreign particles
♦ Engine runs properly
n AG. Volkswagen AG do
wage es n
Select a stretch of road for the road test on which all the functions y V olks ot g
ua
of the gearbox can be evaluated “shifting, various speed, driving ed b ran
ris
forwards and reversing”. utho tee
or
a ac
ss
8.1 Vehicle cannot drive forwards or backwards

ce
le
un

pt
an
d
itte

Possible causes of fault Rectifying fault

y li
rm

ab
pe

ility
Multifunction switch -F125- defective – Check multi-function switch -F125- .
ot

♦ Contacts in switch damaged

wit
, is n

h re
– To do this, connect one of the Volkswagen testers
hole

♦ Wiring or connection to switch defective or not ⇒ page 43 .

spec
connected according to current flow diagram
es, in part or in w

t to the co
– Check wiring according to current flow diagram and
repair if necessary ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.

rrectness of i
– For gearboxes 096, 01M, 098, 01P and 099 beginning
l purpos

February 1994, check pin assignment to multifunction

switch -F125- according to current flow diagram and
change if necessary ⇒ Current flow diagrams, Electri‐
nform
ercia

cal fault finding and Fitting locations.

m

a
com

♦ Wires as well as seals of wiring harness defec‐ – Renew wiring and connections ⇒ Current flow dia‐
tion in

tive grams, Electrical fault finding and Fitting locations.

r
te o

thi
s
iva

do

Plug in valve body broken. – Remove pan from gearbox and check that all plugs in
r
rp

cum

side of valve body are present.

fo

en
ng

t.
yi
Selector lever cable loose in its cable support: – Renew retaining clip
Co
op py
Retaining clip defective or not engaged.
. C rig
ht ht
rig
Some vehicles do not have this retaining clip. In this or py by
co Vo
case, the selector lever cable is clipped into its ca‐ – Renew selector lever cable ⇒ page 65 .
by lksw
cted agen
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ble support. This clip on the selector lever cable
AG.

could be broken.
The drive plate is fractured because the centring – Renew drive plate and centring sleeve for engine and
sleeve in the engine/gearbox flange are missing. gearbox ⇒ Engine workshop manual for installed en‐
gine (allocation according to engine code) .

24 Rep. Gr.00 - Technical data

 AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Passat 1997 ➤
e
horis 4-speed automatic
nte
eo gearbox 01N - Edition 10.2005
aut ra
ss c
8.2 Vehicle will not drive forwards

ce
e
nl

pt
du

an
itte

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Possible causes of fault erm Rectifying fault

ab
ility
1st through 3rd gear clutch -K1- -K1- defective – Repair 1 - 1st through 3rd gear clutch -K1-
ot p

wit
⇒ page 111 .
, is n

h re
hole

spec
es, in part or in w

t to the co
8.3 Vehicle will not reverse
Possible causes of fault Rectifying fault

rrectness of i
♦ Reverse gear brake -B1- defective – Repair reverse gear brake -B1- and/or reverse gear
l purpos

clutch -K2- ⇒ page 111 .

♦ Reverse gear clutch -K2- defective

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ercia

orm
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c

8.4 Gearbox oily

or

thi
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sd
iva

o
Possible causes of fault Rectifying fault
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rp

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m
f

en
ng

♦ Seals or components on exterior of gearbox – Clean engine and gearbox and localise leak on gear‐
t.
yi Co
leaking box, if necessary. Use oil leak detector spray -G 001
Cop py
ht. rig
900 A1- .
rig ht
♦ Gearbox leaking
py by
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– If gearbox is leaking, seal or renew defective compo‐
cted agen
Prote AG.
nents.

– Renew oil seals, gaskets, threaded connections or

gearbox housing (torque converter housing)
⇒ page 111 .
Engine leaking – Seal engine ⇒ Engine workshop manual for installed
engine (allocation according to engine code) .
⇒ ATF level too high; ⇒ ATF escapes from breather – Clean gearbox.

– Checking ⇒ ATF level ⇒ page 100 .

8.5 Oil or ⇒ ATF leaks around torque converter

Possible causes of fault Rectifying fault
♦ If it is engine oil: crankshaft seal is leaking – Remove gearbox and renew crankshaft seal

⇒ Engine workshop manual for installed engine (alloca‐

tion according to engine code)
♦ If it is ⇒ ATF: – Adjust drive plate clearance ⇒ Engine workshop man‐
ual for installed engine (allocation according to engine
Clearance of drive plate not correct code) .
Torque converter seal leaking – Renew torque converter seal; if running surface of tor‐
que converter is damaged, renew torque converter
also ⇒ page 41 .
Torque converter bush defective – Renew torque converter ⇒ page 37 .
⇒ ATF pump leaking – Dismantle ⇒ ATF pump, renew defective components
and assemble ⇒ page 165 .

– Check torque converter for damage (visual check).

8. Fault finding for the automatic 4-speed gearbox 25

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.6 Visible fouling of ⇒ ATF and/or engine coolant

Possible causes of fault Rectifying fault
⇒ ATF cooler defective, allowing ⇒ ATF and coolant • Prerequisite: no engine oil in coolant (cylinder head
to mix. gasket etc. okay)
– Renew ⇒ ATF cooler.

– Renew coolant and ⇒ ATF; if necessary renew ⇒ ATF

a second time.
Coolant can damage seals and clutch plates in the gear‐
box. After renewing coolant and ⇒ ATF:
– Perform road test, checking “position of shift elements”
⇒ page 105 .

If problems in operation occur, the gearbox must be re‐

paired ⇒ page 111 .

AG. Volkswagen AG d
agen oes
ksw
8.7 ⇒ ATF level too low, final drive oil level d by
Vol not
gu
ara
too high (or vice versa) - no external ise nte
or eo
h
ut
leaks in gearbox a ra
ss c

ce
e
nl

pt
Only for gearboxes with 2 separate oil systems
du

an
itte

y li
erm

ab
Possible causes of fault Rectifying fault

ility
ot p

Seal for output shaft/pinion shaft defective; ⇒ ATF – Renew seal for output shaft ⇒ Rep. Gr. 38 ; Removing

wit
, is n

h re
and final drive oil have mixed. and installing output shaft ; Gearbox - longitudinal in‐
hole

stallation ⇒ Rep. Gr. 39 ; Removing and installing

spec
output shaft .
es, in part or in w

t to the co
rrectness of i
8.8 Gearbox oily only near breather - no other external leaks in gearbox
l purpos

Possible causes of fault Rectifying fault

♦ Too much ⇒ ATF was added – Check ⇒ ATF meticulously ⇒ page 100 .

nf
ercia

orm
m

♦ Seal for output shaft/pinion shaft defective; ⇒ – To rectify fault, see ⇒ page 26 . atio
om

ATF and final drive oil have mixed so much that

n in
or c

fluid escapes through the breather.

thi
te

sd
iva

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f

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ng

t.
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op
8.9 ⇒ ATF escaping from breather (only for longitudinally installed gearbox 01N)
C py
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Possible causes of fault Rectifying fault
lksw
cted agen
Prote AG.
If the ⇒ ATF level is correct, then baffle plate in – Attach breather hose -01N 409 831- to breather pipe
gearbox is not working properly. and route in engine compartment.

– Clean gearbox, check ⇒ ATF level ⇒ Rep. Gr. 37 ;

Checking and topping up ⇒ ATF level .

– Carry out test drive.

8.10 Selector mechanism does not move freely

Possible causes of fault Rectifying fault
– Pry selector lever cable off selector shaft lever.

26 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Possible causes of fault Rectifying fault

n AG. Volkswagen AG do
External part of selectorlksmechanism
wage does not movees n If the external part of the selector mechanism does
ot g
not
freely. d by
Vo
move
ua freely:
ran
rise – Repairing
tee selector mechanism ⇒ page 54 .
tho or
au a
ss – Alwaysc renew kinked selector lever cable.

ce
e
nl

Selector mechanism in gearbox does not move If the selector mechanism in the gearbox does not move

pt
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an
freely freely:
itte

y li
erm

– Dismantling and assembling ⇒ parking lock

ab
ility
⇒ page 192 .
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hole

spec
es, in part or in w

8.11 Not all selector lever positions can be selected; selected drive ranges do

t to the co
not function

rrectness of i
Possible causes of fault Rectifying fault
l purpos

Selector lever cable loose in its cable support: – If present, renew securing clip
Retaining clip defective or not engaged.
Some vehicles do not have this retaining clip. In this – Renew selector lever cable ⇒ page 65 .

nform
ercia

case, the selector lever cable is clipped into its ca‐

ble support. This clip on the selector lever cable
m

at
om

could be broken.

ion
c

in t
or

his
ate

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priv

cum

8.12 ⇒ Parking lock does not engage

for

en
ng

t.
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op py
Possible causes of fault Rectifying fault
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Selector lever cable defective or incorrectly adjus‐ – Check and adjust selector lever cable.
op Vo
by c lksw
cted
ted
agen
Prote AG.
– Renew and adjust selector lever cable ⇒ page 65 .
Selector lever cable loose in its cable support: – Renew retaining clip
Retaining clip defective or not engaged.
Some vehicles do not have this retaining clip. In this or
case, the selector lever cable is clipped into its ca‐ – Renew selector lever cable ⇒ page 65 .
ble support. This clip on the selector lever cable
could be broken.
Detent lever, parking lock gear or detent lever – Repairing detent lever, parking lock gear and mecha‐
mechanism defective nism for detent lever ⇒ page 192 .
For vehicles with ignition key withdrawal lock: – Check and adjust locking cable ⇒ page 55 .
♦ Lock cable loose, not adjusted

8.13 ⇒ Parking lock disengages “with a jolt” (selector lever sometimes difficult to
move from “P” to “R”)
Possible causes of fault Rectifying fault
Load change reaction of detent lever for parking – Apply handbrake before engaging ⇒ parking lock.
lock gear, when:
vehicle is parked on an incline or the detent of the
⇒ parking lock is under tension due to being switch‐
ed on and off repeatedly.

8.14 Final drive noisy

Possible causes of fault Rectifying fault
Tapered roller bearing loud – Renew tapered roller bearing ⇒ page 207

8. Fault finding for the automatic 4-speed gearbox 27

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Possible causes of fault Rectifying fault

Output shaft loud – Renew output shaft ⇒ page 212 .
Output shaft loud – Renewing output gear 1) ⇒ page 212 .
Input gear loud – Renewing input gear 1)
⇒ page 208 .
Final drive gear set (pinion shaft with crown gear) – Renewing final drive gear set ⇒ page 219 .
loud
1) Always renew together.

8.15 Performance - jolting in neutral or during certain engine and gearbox move‐
ments
Possible causes of fault Rectifying fault
Throttle valve housing leaking – Check throttle valve housing and air duct for leaks ⇒
Engine workshop manual for installed engine (alloca‐
tion according to engine code) .

n AG. Volkswagen AG do
lkswage es n
o ot g
yV
8.16 Engine speed drops when driving range is selected d b ua
ran
ir se tee
tho
u or
Possible causes of fault ss
a
Rectifying fault ac

ce
le

Park/neutral (P/N) signal is not detected by engine – Check P/N signal.

un

pt
an
d

control unit.
itte

y li
rm

– To do this, connect one of the Volkswagen testers

ab
pe

ility
⇒ page 43 .
ot

wit
, is n

h re
– Check wiring and connections according to current
hole

spec
flow diagram and repair if necessary ⇒ Current flow
es, in part or in w

diagrams, Electrical fault finding and Fitting locations.

t to the co
Engine control unit defective – Perform ⇒ self-diagnosis on engine control unit gui-
ded fault finding
rrectness of i

– To do this, connect one of the Volkswagen testers

l purpos

⇒ page 43 .

– Renew engine control unit ⇒ Rep. Gr. 24 .

nform
mercia

a
com

tion in

8.17 Vehicle does not start or also starts in “R-D-3-2-1”

r
te o

thi
s
iva

do
r

Possible causes of fault Rectifying fault

rp

cum
fo

en
ng

Wiring of multifunction switch -F125- or starter in‐ – Check wiring according to current flow diagram ⇒ Cur‐
t.
yi Co
op
hibitor and reversing light relay -J226- defective rent flow diagrams, Electrical fault finding and Fitting
C py
t. rig
locations.
gh ht
pyri by
Vo
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Multifunction switch -F125- defective
by
– Check multi-function switch -F125- . Prote
cted AG.
agen

– To do this, connect one of the Volkswagen testers

⇒ page 43 .
Starter inhibitor and reversing light relay -J226- de‐ – Renew relay ⇒ Current flow diagrams, Electrical fault
fective finding and Fitting locations;

28 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.18 Vehicle does not start or engine stalls after a short time
Possible causes of fault Rectifying fault
♦ If faults 00545 and 00638 are stored in auto‐ – Check wiring according to current flow diagram ⇒ Cur‐
matic gearbox control unit -J217- : rent flow diagrams, Electrical fault finding and Fitting
locations; if necessary renew current supply relay for
Loose contact in current supply relay for engine engine control unit.
control unit

8.19 Selector lever can be moved from “N” or “P” without brake being operated
Possible causes of fault Rectifying fault
Selector lever lock solenoid -N110- defective – CheckAG. Vselector
olkswagenlever
AG do lock solenoid -N110- .
agen es n
lksw
V – To do this, connect oneoof
o
the
ara Volkswagen testers
t gu
d by
o rise ⇒ page 43 . nte
eo
h
ut
Open circuit in wiring to selector lever lock
ss a solenoid – Check wiring according to current ra
flow
c diagram ⇒ Cur‐
-N110- rent flow diagrams, Electrical fault finding and Fitting

ce
e
nl

pt
locations.
du

an
itte

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No signal from brake light switch -F- – Check wiring according to current flow diagram ⇒ Cur‐
erm

ab
rent flow diagrams, Electrical fault finding and Fitting

ility
ot p

locations.

wit
, is n

h re
hole

– Check brake light switch -F- .

spec
es, in part or in w

t to the co
– To do this, connect one of the Volkswagen testers
⇒ page 43 .
♦ “No fault detected” appears in display -VAS – Renew control unit ⇒ page 48 .

rrectness of i
5051-
l purpos

Automatic gearbox control unit -J217- defective

nf
ercia

orm
m

8.20 Selector lever cannot be moved from “N” or “P” although brake is operated
atio
om

n in
or c

Possible causes of fault Rectifying fault

thi
te

sd
iva

Brake light switch -F- defective/no signal – Check brake light switch -F- .
r
rp

cu
o

m
f

en
ng

t.
– To do this, connect one of the Volkswagen testers
yi Co
op
⇒ page 43 .
C py
t. rig
gh ht
pyri by
Vo
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by c Fitting location of switch ⇒ page 53
lksw
cted agen
Prote AG.
Brake light switch -F- wiring defective – Check wiring according to current flow diagram ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting
locations.

8.21 Shifts occur sporadically or not at all

Possible causes of fault Rectifying fault
Only for gearboxes “01M, 01P” from January 1995: – Interchange connectors.
Connectors for vehicle speed sender -G68- and
gearbox speed sender -G38- interchanged. – Carry out test drive.

– To do this, connect one of the Volkswagen testers

⇒ page 43 .

8. Fault finding for the automatic 4-speed gearbox 29

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Possible causes of fault Rectifying fault

Multifunction switch -F125- defective – Check multi-function switch -F125- .
♦ Contacts in switch damaged
– To do this, connect one of the Volkswagen testers
♦ Wiring or connection to switch defective or not ⇒ page 43 .
connected according to current flow diagram
– Check wiring according to current flow diagram and
repair if necessary ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.

– For gearboxes 096 and 098 until February 1994, check

AG. Volkswagen AG d pin assignment to multifunction switch -F125- accord‐
agen oesing to current flow diagram and change if necessary
olksw not
ed by
V
⇒ Current
gu
ara flow diagrams, Electrical fault finding and
horis Fitting locations.
nte
e
t or
au ac
ss
– For gearboxes 096, 01M, 098, 01P and 099 beginning

ce
e

February 1994, it is essential to check pin assignment

nl

pt
du

an
to multifunction switch -F125- according to current flow
itte

y li
diagram and change if necessary ⇒ Current flow dia‐
erm

ab
grams, Electrical fault finding and Fitting locations.

ility
ot p

wit
, is n

♦ Wires as well as seals of wiring harness defec‐ – Renew wiring and connections ⇒ Current flow dia‐

h re
tive grams, Electrical fault finding and Fitting locations.
hole

spec
es, in part or in w

Plug in valve body broken. – Remove pan from gearbox and check that all plugs in

t to the co
side of valve body are present.
Manual selector valve or spool valve in valve body – Perform road test with -VAS 5051- and check whether

rrectness of i
jammed all spool valves and selector elements are actuated
during the drive ⇒ page 105 .
l purpos

– Renew valve body, ⇒ ATF and ⇒ ATF strainer

⇒ page 181 .
nf
ercia

orm

• Only gearboxes “096, 01M, 098, 099 and 01P” – Renew input gear ⇒ Rep. Gr. 39 ; Dismantling and
m

atio
m

assembling final drive .

o

Impulse wheel for vehicle speed sender -G68-

n in
or c

loose or broken
thi
te

sd
iva

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rp

cu
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m
f

en
ng

t.
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8.22 All shifts are “hard or jolting”
Co
Cop py
t. rig
gh ht
yri by
Possible causes of fault Rectifying fault
op Vo
by c lksw
cted agen
Prote
• Only for gearboxes “01M, 01P” from January – Perform basic setting with engine switched off
AG.

1995; ⇒ page 45 .
Connectors for vehicle speed sender -G68- and – Interchange connectors.
gearbox speed sender -G38- interchanged.
In this case, when fault memory is read, “Sender – Carry out test drive.
for gearbox speed -G38-/implausible signal” will be
displayed.
• Only gearbox “001” – Check wiring and connections according to current
flow diagram and repair if necessary ⇒ Current flow
No signal from gearbox oil temperature sender - diagrams, Electrical fault finding and Fitting locations.
G93- /Sender defective
– Check gearbox oil temperature sender -G93- and re‐
new if necessary.
Throttle valve potentiometer signal is not detected – Check signal from throttle valve potentiometer.
by automatic gearbox control unit -J217- .
– To do this, connect one of the Volkswagen testers
⇒ page 43 .

– Perform ⇒ self-diagnosis of engine control unit.

– Check wiring and connections according to current

flow diagram and repair if necessary ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

30 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Possible causes of fault Rectifying fault

Connection to gearbox damaged or loose (connec‐ – Check wiring and connections according to current
tion: conductor strip input wire connector in vehicle flow diagram and repair if necessary ⇒ Current flow
wiring harness) diagrams, Electrical fault finding and Fitting locations.
♦ Contacts dirty or corroded
♦ Connector contact in connector housing dam‐
aged (not engaged)

Short circuit between valve lines on conductor strip – Renew valve circuits (conductor strip) ⇒ page 181 .
or cable guide rail
Wrong control unit installed or control unit defective – Read out control unit identification.

– To do this, connect one of the Volkswagen testers

⇒ page 43 .

– Select control unit according to ⇒ Electronic parts

catalogue “ETKA” and renew.
Manual selector valve or spool valves in valve body – Renew valve body ⇒ page 181 .
defective

8.23 One particular shift is “hard or jolting”

AG. Volkswagen AG d
agen oes
Possible causes of fault
Vol
ksw nRectifying
ot g fault
by ua
Selector element ed
is(clutch or brake) defective
ran
Check twhich gear changes have a hard shift:
r ee
tho – To do othis, connect one of the Volkswagen testers
au ra
ss ⇒ page 43 . c
ce
e
nl

pt
du

– Carry out test drive. The table “positions of selector el‐

an
itte

y li

ements ” provide information about which selector el‐

erm

ab

ements are affected ⇒ page 105 .

ility
ot p

wit
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– Renew affected selector elements.

h re
hole

spec
es, in part or in w

t to the co

8.24 Shift from 3rd to 4th gear takes “too long” in vehicles through 12.92 having
economy/sport switch
rrectness of i
l purpos

Possible causes of fault Rectifying fault

When shifting from 3rd to 4th gear, the gearboxes No fault rectification, as this shift is a result of the design.
nf
ercia

in these vehicles split the load. Therefore, under

o

certain driving situations, the shift from 3rd to 4th

rm
m

atio

may seem to take “too long”.

om

n in
or c

thi
te

sd
iva

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8.25 Shifts take “too long”

rp

cu
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m
f

en
ng

t.
yi Co
Possible causes of fault Rectifying fault
Cop py
t. rig
gh ht
yri
A clutch or a brake is defective Check which gear changes have a hard shift:
p by
o Vo
by c
– To do this, connect one of the Volkswagen testers
lksw
cted agen
Prote
⇒ page 43 .
AG.

– Carry out test drive. The table “positions of selector el‐

ements ” provide information about which selector el‐
ements are affected ⇒ page 105 .

– Renew affected selector element(s).

Vehicles through 12.92 with an E/S switch split the load

when shifting from 3rd to 4th gear.

8. Fault finding for the automatic 4-speed gearbox 31

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Possible causes of fault Rectifying fault

Valve stuck in valve body – Renew valve body ⇒ page 181 .
Torque converter defective – Renew torque converter ⇒ page 37 .

8.26 Hard shifts immediately after repair

Possible causes of fault Rectifying fault
♦ “No fault detected” appears in display -VAS – Carry out basic settings ⇒ page 45 .
5051-
♦ Damage to wiring has been excluded (connec‐
tors)
Basic setting has not been initiated

8.27 Gearbox downshifts at constant vehicle speed without apparent reason

Possible causes of fault Rectifying fault
⇒ ATF is insufficiently cooled and gearbox down‐ – Check why ⇒ ATF temperature rises about its specified
shifts as a safety function. limit. Check for additional components or changes to
vehicle which may affect the cooling. The subsequent
installation of a trailer hitch without the necessary
change of the radiator fan can lead to cooling prob‐
lems.
Engine speed signal is not detected by automatic – Connect one of the Volkswagen testers ⇒ page 43
gearbox control unit -J217- . and check if the signal is detected.

– Check wiring and connections according to current

flow diagram and repair if necessary ⇒ Current flow
AG. Volkswagen AG d diagrams, Electrical fault finding and Fitting locations.
agen oes
olksw not
byV gu
a
rised
– Performran⇒te self-diagnosis of engine control unit.
tho eo
au ra
ss – To do this, connect
c one of the Volkswagen testers
⇒ page 43 .
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

8.28 Gearbox does not downshift for kickdown

wit
, is n

h re
hole

Possible causes of fault Rectifying fault

spec
es, in part or in w

Kickdown switch -F8- defective or no signal – Check kickdown switch -F8- signal and
t to the co

– Carry out basic setting ⇒ page 45

rrectness of i

– Check wiring according to current flow diagram and

repair if necessary ⇒ Current flow diagrams, Electrical
l purpos

fault finding and Fitting locations.

Throttle valve potentiometer signal is not detected – Check signal from throttle valve potentiometer and
nf
ercia

by automatic gearbox control unit -J217- .

rm
m

– Perform ⇒ self-diagnosis of engine control unit.

atio
om

n in
or c

– To do this, connect one of the Volkswagen testers

thi
e

⇒ page 43 .
t

sd
iva

o
r
rp

cu
o

– Check wiring and connections according to current

f

en
ng

t.
flow diagram and repair if necessary ⇒ Current flow
yi Co
op py
diagrams, Electrical fault finding and Fitting locations.
. C rig
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rig by
copy Vo
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cted agen
Prote AG.

32 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.29 Gearbox does not shift until it warms up

Possible causes of fault Rectifying fault
Manual selector valve or spool valves in valve body – Renew valve body ⇒ page 181 .
defective
♦ Only gearbox 001:
When the ⇒ ATF temperature is under 15°C, this
gearbox will not shift into 4th gear. This is not a
fault.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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8.30 Gearbox switches to emergency running th eo
au ra
ss c

ce
le

Possible causes of fault Rectifying fault

un

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d
itte

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Also see ⇒ page 30
rm

ab
pe

ility
Connection to gearbox damaged or loose (connec‐ – Check wiring and connections according to current
ot

wit
tion: conductor strip input wire connector in vehicle flow diagram and repair if necessary ⇒ Current flow
, is n

h re
wiring harness) diagrams, Electrical fault finding and Fitting locations.
hole

♦ Contacts dirty or corroded

spec
es, in part or in w

t to the co
♦ Connector contact in connector housing dam‐
aged (not engaged)
♦ Short circuit or open circuit in wiring harness

rrectness of i
l purpos

Short circuit or open circuit between valve circuits – Perform ⇒ self-diagnosis and ⇒ electrical check and
(conductor strip), cable guide rail or wires to spool then renew wiring or component.
valves.

nform
ercia

– To do this, connect one of the Volkswagen testers

⇒ page 43 .
m

a
com

tion in
– Renew valve circuits (conductor strip) ⇒ page 181 .
r
te o

thi
Plug in valve body broken. – Remove pan from gearbox and check that all plugs in
s
iva

do
r

side of valve body are present.

rp

cum
fo

en
g

Valve stuck in valve body – Renew valve body ⇒ page 181 .

n

t.
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op py
♦ “No fault detected” appears in display -VAS – Read out control unit identification.
t. C rig
gh ht
5051- yri
p by
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– To do this, connect one of the Volkswagen testers
c by lksw
cted
Wrong control unit installed or control unit defective
agen
⇒ page 43 .
Prote AG.

– Select control unit according to ⇒ Electronic parts

catalogue “ETKA” , compare and renew if necessary.

8.31 Selector lever position “1”, gearbox does not shift to 1st gear (no power
transfer in 1st gear)
Possible causes of fault Rectifying fault
1st through 3rd gear clutch -K1- or reverse gear – Refer to the positions of the selector elements on
brake -B1- defective ⇒ page 105 .

– Repair 1st through 3rd gear clutch -K1- or freewheel

⇒ page 111 .

8. Fault finding for the automatic 4-speed gearbox 33

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.32 Selector lever position “D”, “3” or “2”, gearbox does not shift to 1st gear (no
power transfer)
Possible causes of fault Rectifying fault
1st through 3rd gear clutch -K1- or freewheel de‐ – Refer to the positions of the selector elements on
fective ⇒ page 105 .

– Repair 1st through 3rd gear clutch -K1- or freewheel

⇒ page 111 .

8.33 Selector lever position “D”, “3” or “2”, automatic gearbox does not shift to
2nd gear (no power transfer)
Possible causes of fault Rectifying fault
2nd and 4th gear brake -B2- defectiveagen AG. Volkswag–en ARefer
G do to the positions of the selector elements
Volks
w ⇒ page
es n 105 .
ot g
by ua
d ran
ir se
tho – Repair 2nd and
tee 4th gear brake -B2- ⇒ page 111
or .
au ac
ss

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an
8.34 Selector lever position “D” or “3” does
itte

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erm

ab
not shift to 3rd gear, hydraulic (3H)
ility
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wit
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Gearboxes through manufacture date 12.92 (not 001)

h re
hole

⇒ page 34
spec
es, in part or in w

Automatic gearboxes from manufacture date 01.95 (not 001) t to the co

⇒ page 34
Gearbox 001 ⇒ page 34
rrectness of i

8.34.1 Automatic gearboxes through manufacture date 12.92

l purpos

Possible causes of fault Rectifying fault

nf
ercia

Reverse gear clutch -K2- defective – Refer to the positions of the selector elements
rm
m

⇒ page 105 .
atio
om

n in
c

– Repairing reverse gear clutch -K2- ⇒ page 111 .

or

thi
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sd
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ng

8.34.2 Automatic gearboxes from manufacture date 01.95

t.
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t. rig
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Possible causes of fault Rectifying fault
p by
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cted agen
3rd and 4th gear clutch -K3- defective Prote – Refer to the positions of the selector elements
AG.
⇒ page 105 .

– Repair 3rd and 4th gear clutch -K3- ⇒ page 111 .

8.34.3 Automatic gearbox 001

Possible causes of fault Rectifying fault
3rd and 4th gear clutch -K3- – Refer to the positions of the
defective selector elements
⇒ page 105 .

– Repair 3rd and 4th gear clutch

-K3- ⇒ page 111 .

34 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.35 Selector lever position “D” or “3” does

not shift to 3rd gear, mechanical (3M)

8.35.1 Automatic gearboxes through manufacture date 12.92, not gearbox 001
Possible causes of fault Rectifying fault
3rd and 4th gear clutch -K3- defective – Refer to the positions of the selector elements
⇒ page 105 .

– Repair 3rd and 4th gear clutch -K3- ⇒ page 111 .

n AG. Volkswagen AG do
wage es n
8.35.2 Automatic gearboxes from manufacture date 01.95 and gearbox 001
olks ot g
byV ua
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ir se tee
o
Possible
au causes of fault
th Rectifying
or
ac fault
ss
Lock-up clutch defective – Refer to the positions of the selector elements

ce
le
un

pt
⇒ page 105 .

an
d
itte

y li
rm

ab
– Renew torque converter ⇒ page 37 .
pe

ility
ot

wit
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h re
hole

spec
8.36 Selector lever position “D” or “3” does
es, in part or in w

t to the co
not shift to 3rd gear (not gearbox 001)
rrectness of i

8.36.1 Automatic gearboxes from manufacture date 01.93 through 12.94

l purpos

Possible causes of fault Rectifying fault

nform
ercia

Reverse gear clutch -K2- defective – Refer to the positions of the selector elements
⇒ page 105 .
m

a
com

tion in

– Repairing reverse gear clutch -K2- ⇒ page 111 .

r
te o

thi
s
iva

do
r
rp

cum
fo

en
g

8.37 Selector lever position “D” does not shift

n

t.
yi Co
op
to 4th gear
C py
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pyri by
Vo
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by
cted agen
Prote AG.

8.37.1 Automatic gearboxes from manufacture date 01.93 through 12.94

Possible causes of fault Rectifying fault
4th gear clutch -K3- defective – Refer to the positions of the selector elements
⇒ page 105 .

– Repair 4th gear clutch -K3- ⇒ page 111 .

8. Fault finding for the automatic 4-speed gearbox 35

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.38 Selector lever position “D” does not shift

to 4th gear, mechanical (4M)

8.38.1 Automatic gearboxes from manufacture date 01.95 and gearbox 001
Possible causes of fault Rectifying fault
Lock-up clutch defective – Refer to the positions of the selector elements
⇒ page 105 .

– Renew torque converter ⇒ page 37 .

8.39 Selector lever position “R”, automatic gearbox does not shift to reverse gear
Possible causes of fault Rectifying fault
Reverse gear clutch -K2- defective – Repair reverse gear clutch -K2- or reverse gear brake
Reverse gear brake -B1- defective -B1- ⇒ page 37 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

36 Rep. Gr.00 - Technical data

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

32 – Torque converter
1 ⇒ Torque converter

1.1 Assembly overview

1 - ⇒ Torque converter
❑ Secure in place when AG. Volkswagen AG d
gearbox is removed agen oes
olksw not
⇒ page 86 . byV gu
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❑ Codes ⇒ page 7uth. o eo
ra
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❑ Checking ⇒ pagess 42 . c

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e
nl

❑ Installing ⇒ page 42

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itte

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❑ Installation (new) di‐
erm

ab
mension ⇒ page 42 .

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2 - Seal
, is n

h re
hole

❑ Renewing ⇒ page 41

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

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or c

thi
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sd
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f

en
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

1.2 Identification of ⇒ torque converter

There are various ⇒ torque converters.
Previous ⇒ torque converter with sleeve bearing in turbine shaft
of gearbox.
New ⇒ torque converter with integrated needle bearing.
They are identified by codes.

1. Torque converter 37
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
n AG. Volkswagen AG do
The previous ⇒ torque converter may be installed olks
wonly
age in gear‐ es n
ot g
boxes with a sleeve bearing in the turbine shaft.
d b For identification,
y V ua
ran
the fourth letter is “C”. or
ise tee
th or
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ss

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pt
an
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itte

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ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

t to the co
The new ⇒ torque converter may be installed only in gearboxes
without a sleeve bearing in the turbine shaft. For identification, the

rrectness of i
fourth letter is “D”.
l purpos

If a new ⇒ torque converter with integrated needle bearing is in‐

stalled in a gearbox with a sleeve bearing in the turbine shaft,

nform
ercia

remove the sleeve bearing ⇒ page 38 .

m

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tion in
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thi
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Cop py
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1.3 Allocation of ⇒ torque converter rig ht
py by
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by lksw
cted
There are two versions, allocated according to gearbox codes
agen
Prote AG.
⇒ page 7 .
Previous ⇒ torque converter with sleeve bearing in turbine shaft
of gearbox -arrow-.
New ⇒ torque converter with integrated needle bearing. In this
version, no sleeve bearing -arrow- may be in the turbine shaft of
the gearbox. Remove the sleeve bearing if necessary.

1.4 Removing sleeve bearing from turbine

shaft
Set down gearbox in installation position on gearbox pan.
– Remove ⇒ torque converter.

38 Rep. Gr.32 - Torque converter

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Position holes -A- of turbine shaft horizontally.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
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ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Protect gearbox by carefully covering turbine shaft and holes
with tape.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
– Saw open sleeve bearing using a saw blade. Do not place saw
yi Co
op
blade onto joint -arrow- of sleeve bearing when doing this.
C py
ht. rig
rig ht
py by
– Make sure no metal shavings fall into gearbox. co Vo
by lksw
cted agen
Prote AG.

– Use a screwdriver to lever off sawn open sleeve bearing care‐

fully, without damaging turbine shaft.
– Remove metal shavings and tape.
Now renew ⇒ torque converter seal.

1.5 Draining ⇒ torque converter

Special tools and workshop equipment required

1. Torque converter 39
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Oil extraction unit -V.A.G 1358 A- AG. Volkswagen AG d

agen oes
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V gu
d by ara
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or eo
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aut ra
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pt
du

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itte

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erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
♦ Oil extraction probe -V.A.G 1358 A/1-

rrectness of i
If ⇒ ATF has become fouled by abraded material or if a major
overhaul of gearbox is being performed, drain ⇒ torque converter
l purpos

as follows:
– Extract ⇒ ATF from ⇒ torque converter using -V.A.G 1358 A-

nform
ercia

and probe -V.A.G 1358 A/1- .

m

at
om

Clean ⇒ ATF lines and ⇒ ATF cooler ⇒ page 111 .

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

40 Rep. Gr.32 - Torque converter

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1.6 Removing and installing ⇒ torque con‐

verter seal
Special tools and work‐
shop equipment re‐
quired
♦ Extractor tool -
VW 681-

♦ Thrust piece -
T10129- AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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ce
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un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Removing ⇒ torque con‐
verter seal

rrectness of i
Driving in ⇒ torque converter seal flush
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Torque converter 41
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1.7 Checking ⇒ torque converter

– Check torque converter hub for scoring -arrow-.
The ⇒ torque converter is welded and must be renewed if dam‐
aged.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
1.8 Installing ⇒ torque converter a ra
ss c

ce
le
un

pt
Special tools and workshop equipment required

an
d
itte

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♦ Depth gauge
rm

ab
pe

ility
ot

– Push on torque converter hub through seal to first stop.

wit
, is n

h re
– Turn ⇒ torque converter towards gearbox using light pressure
hole

spec
until notch in hub engages in follower of pump gear and ⇒
es, in part or in w

torque converter can be felt to slip in place.

t to the co
Checking installation dimensions of ⇒ torque converter

rrectness of i
– When the torque converter is properly inserted in the gearbox,
distance -A- between the contact surface at the base of the
l purpos

stud on the ⇒ torque converter and the contact surface of the

bell housing is about 23 mm.

nform
ercia

If the torque converter is not installed completely, the distance is

approx. 13 mm.
m

a
com

tion in
r
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Caution

thi
s
iva

do
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rp

c
If the torque converter is improperly installed, the follower of

um
fo

en
the converter or ⇒ ATF pump will be destroyed when the gear‐
ng

t.
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box is bolted onto the engine. t. Cop py
rig
gh ht
pyri by
Vo
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by c lksw
cted
During subsequent installation, observe in particular the following
agen
Prote AG.
points:
When tightening bolts on engine/gearbox flange, check repeat‐
edly that the ⇒ torque converter can still be turned behind the drive
plate.
If the torque converter cannot be turned, it can be assumed that
it is not properly installed and that the follower of the ⇒ torque
converter or the ⇒ ATF pump will be destroyed during the final
tightening of the threaded connections.

42 Rep. Gr.32 - Torque converter

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

37 – Controls, housing
1 Connecting Volkswagen tester and
selecting functions
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS 5051-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c

ce
le
un

pt
an
d
itte

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♦ Diagnosis lead, 3m with voltage supply -VAS 5051/1- or diag‐
rm

ab
nosis lead, 5m without voltage supply -VAS 5051/3-
pe

ility
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wit
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Additional required information

h re
hole

spec
♦ ⇒ Self-study programme No. 292 ; Vehicle diagnosis, testing
es, in part or in w

and information system VAS 202

t to the co
WARNING

rrectness of i
♦ During a test drive, always secure testing and measuring
l purpos

equipment on the back seat.

♦ These devices may be operated only by a passenger dur‐

nform
ercia

ing a test drive.

m

a
com

tion in
r

Vehicles through 09.00

te o

thi
s
iva

do

– Remove cover above diagnostic connection on right next to

r
rp

cum

handbrake lever.
fo

en
ng

t.
yi Co
– With ignition switched off, connect tester -VAS 5051- to diag‐ Cop py
nostic connection with diagnostic lead -VAS 5051/1- or -
t. rig
gh ht
yri by
VAS 5051/3- . op Vo
by c lksw
cted agen
Prote
Vehicles from 10.00
AG.

1. Connecting Volkswagen tester and selecting functions 43

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– With ignition switched off, connect tester -VAS 5051- to diag‐

nostic connection with diagnostic lead -VAS 5051/1- or -
VAS 5051/3- .
Continuation for all vehicles

– Switch on tester -arrow-.

n AG. Volkswagen AG do
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The tester is ready for use yV
o when it is possible to choose
lks es n
otbetween
gu
the buttons guided isfunctions
ed
b and guided fault finding ara on
nte
the “right” of the uscreen.
thor eo
ra
a c
ss
Depending on equipment and version of the tester, other func‐

ce
e

tions may be “displayed” such as:

nl

pt
du

an
itte

y li
♦ ElsaWin
erm

ab
ility
ot p

♦ Testing

wit
, is n

h re
♦ Self-diagnosis
hole

spec
es, in part or in w

The “tester” is now ready for use. t to the co

– Switch on ignition.
– Touch a button on the screen to start the desired function.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

44 Rep. Gr.37 - Controls, housing

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Passat 1997 ➤
aut 4-speed r a automatic gearbox 01N - Edition 10.2005
ss c

ce
e
nl

pt
du

an
2 Carry out basic setting
itte

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ab
ility
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In driving mode, the control unit learns which accelerator pedal

wit
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positions the driver frequently uses at idling speed and full throttle.

h re
For example, carpet under the pedal could hinder the full throttle
hole

spec
position, or constant contact of the driver's foot on the pedal could
es, in part or in w

hinder the idling position.

t to the co
If basic setting is initiated, the learnt valves will be reset to the
standard values programmed by the manufacturer.

rrectness of i
– Connect “tester” and continue to switch until it is ready for op‐
l purpos

eration ⇒ page 43 .
– Press guided functions .

nform
ercia

– Identify vehicle.
m

at
om

io
–

n
c

Select Automatic gearbox 01N

in t
or

his
e

–
at

Perform -J217- basic setting.

do
priv

cum
Always follow the instructions of the tester. It is especially impor‐
for

en
g

tant to completely depress the accelerator pedal once.

n

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Carry out basic setting 45

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3 Electrical and electronic components and their locations

1 - Control unit for automatic

AG. Volkswagen AG d
gearbox -J217- ksw
agen oes
not
Vol
❑ Location ⇒ page 47 d by gu
ara
rise nte
❑ Removing ⇒ page 48 . utho eo
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a
❑ Installing ⇒ page 48 s s c

ce
e
nl

❑ Can be checked using

pt
du

an
“guided fault finding” of -
itte

y li
erm

VAS 5051- .

ab
ility
ot p

❑ Do not renew until after

wit
, is n

determining and cor‐

h re
recting all mechanical
hole

spec
and hydraulic faults and
es, in part or in w

faults on affected elec‐

t to the co
trical and electronic
components; checking
gearbox ⇒ page 75 .

rrectness of i
2 - Engine control unit
l purpos

❑ Location and removing

and installing

nform
ercia

⇒ page 48 .
m

at
3 - Diagnostic connection
om

ion
c

❑ Location in vehicles be‐

in t
or

his
e

fore 09.00 ⇒ page 48 .

at

do
riv

❑ Location in vehicles af‐

p

cum
or

ter 10.00 ⇒ page 49 .

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en
ng

t.
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op
4 - ⇒ Valve body
C py
t. rig
gh ht
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❑ Location ⇒ page 49 p by
co Vo
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❑ Removing and installing
agen
Prote AG.
⇒ page 181
❑ The ⇒ solenoid valves -
N88- , -N89- , -N90- , -
N91- , -N92- , -N93- and
-N94- are attached to
the ⇒ valve body.
❑ Components can be
checked using “guided fault finding” of -VAS 5051- .
5 - Conductor strip with integrated gearbox oil temperature sender -G93-
❑ Location ⇒ page 49
❑ Removing and installing ⇒ page 190
❑ -G93- can be checked using “guided fault finding” in -VAS 5051- .
6 - Multi-function switch -F125-
❑ Location and removing and installing ⇒ page 50 .
❑ Can be checked using “guided fault finding” of -VAS 5051- .
7 - Gearbox speed sender -G38-
❑ Location and removing and installing ⇒ page 50 .
❑ 2-pin connector -T2- to wiring harness is white.
❑ Can be checked using “guided fault finding” of -VAS 5051- .
Do not interchange 2-pin connector -T2- , gearbox speed sender -G38- and driving speed sender -G68- !

8 - Driving speed sender -G68-

❑ Location and removing and installing ⇒ page 51 .

46 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
❑ 2-pin connector -T2- to wiring harness is black.
❑ Can be checked using “guided fault finding” of -VAS 5051- .
Do not interchange 2-pin connector -T2- , gearbox speed sender -G38- and driving speed sender -G68- !

9 - Selector lever lock solenoid -N110-

❑ Location ⇒ page 51
❑ Can be checked using “guided fault finding” of -VAS 5051- .
10 - Throttle valve potentiometer -G69- or accelerator pedal position sender -G79-
❑ More information ⇒ page 51 .
❑ Can be checked using “guided fault finding” of -VAS 5051- .
11 - Cruise control system switch -E45-
❑ Location ⇒ page 51
❑ Removing and installing ⇒ Electrical system; Rep. Gr. 94 ; Removing and installing steering column
switch .
❑ Can be checked using “guided fault finding” of -VAS 5051- .
12 - Kickdown switch -F8-
❑ Location in vehicles without EPC ⇒ page 52 .
❑ Location in vehicles with EPC ⇒ page 52 .
❑ Can be checked using “guided fault finding” of -VAS 5051- .
13 - Starter inhibitor and reversing light relay -J226-
❑ Location ⇒ page 52
14 - Selector lever position display -Y6-
❑ Location ⇒ page 50
❑ Simultaneous illumination of all selector lever position display segments indicates gearbox ⇒ emergency
running mode. wage
n AG. Volkswagen AG do
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15 - Brake light switch -F-eor d b brake pedal switch -F47-
y ua
ran
ris tee
❑ Location and removing
utho and installing ⇒ page 53 . or
a ac
❑ Can be checked ss using “guided fault finding” of -VAS 5051- .
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e
nl

pt
du

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itte

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erm

ab

Location of automatic gearbox control unit -J217-

ility
ot p

wit

The control unit is located in front of the right-hand seat under the
, is n

h re

carpet in footwell.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

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f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Electrical and electronic components and their locations 47

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Removing automatic gearbox control unit -J217-

– Loosen and raise carpet.
– Unclip control unit from box -arrows-.
– Release multi-pin connector and then pull connector off con‐
trol unit.

Installing automatic gearbox control unit -J217-

– Place multi-pin connector on pins of automatic gearbox control
unit -J217- -1- and then lock multi-pin connector -2-.
If engine or gearbox control units are replaced, the system must
be returned to basic setting; performing basic setting ⇒ page 45

Engine control unit

Location: the control unit is located in left plenum chamber.
Removing and installing control unit ⇒ Repair group 23 or ⇒
Repair group 24 . G. Volkswage nA n AG d
wage oes
If engine or gearbox control units are replaced, Volthe system must
ks not
gu
by
be returned to basic setting; performing basic
ise
d setting ⇒ page 45 ara
nte
r
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit

Diagnostic connection in vehicles before 09.00

, is n

h re
hole

Location: diagnostic connection is located in centre console.

spec
es, in part or in w

– Remove cover above diagnostic connection next to handbrake

t to the co

lever.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

48 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Diagnostic connection in vehicles after 10.00

Location: diagnostic connection -arrow- is located below driver
storage compartment.

⇒ Valve body
Location: ⇒ valve body is bolted to underside of gearbox housing
and covered by pan.
The ⇒ solenoid valves -N88- , -N89- , -N90- , -N91- , -N92- , -N93-
and -N94- are attached to the ⇒ valve body.
Removing and installing ⇒ valve body ⇒ page 181

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
Conductor strip with integrated gearbox oil temperature sender -
es, in part or in w

G93-

t to the co
Location: the conductor strip is located in the pan on the ⇒ valve
body.

rrectness of i
The conductor strip can be changed with gearbox installed with‐
l purpos

out removing the ⇒ valve body.

Do not kink or damage the conductor strip. nform
ercia

Removing and installing conductor strip ⇒ page 190 .

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Electrical and electronic components and their locations 49

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Selector lever position display -Y6-

Vehicles through 09.00
Location: in dash panel insert.
Vehicles from 10.00
Location: in dash panel insert with data bus diagnostic interface
-J533-
In ⇒ emergency running with the control unit functioning, all seg‐
ments in the selector lever position display in the dash panel will
light up.
In ⇒ emergency running with a defective control unit, there will be
no display in the selector lever position display.
In vehicles having a data bus, the display for the gearbox control
unit is controlled by the diagnostic interface for the data bus.
Volkswa AG. gen AG
agen does
Removing and installing selector lever Vposition
olks
w
display ⇒ Elec‐ not
gu
trical system; Rep. Gr. 90 ; Dash panel
d by insert; Removing and ara
se nte
installing dash panel insert . tho
ri eo
au ra
c
ss
Multi-function switch -F125-

ce
le
un

pt
an
d
itte

Location: The multi-function switch -arrow- is located on rear of

y li
rm

ab
gearbox.
pe

ility
ot

Removing and installing multi-function switch

wit
, is n

h re
hole

– Pull connector off multi-function switch.

spec
es, in part or in w

– Remove bolt and retainer.

t to the co
– Remove multi-function switch.
– Always renew O-ring.
Install in reverse order of removal. rrectness of i
l purpos

– Tighten bolt to specified torque ⇒ Item 14 (page 194) .

nform
ercia

– Check ⇒ ATF level and top up ⇒ page 100 .

m

a
com

tio

Gearbox speed sender -G38-

n in
r
te o

thi

Location: gearbox speed sender is located top of gearbox on left.

s
iva

do
r
rp

cum

Removing and installing gearbox speed sender

fo

en
ng

t.
yi Co
– Pull white connector off sender. t. Cop py
rig
gh ht
– Remove bolt and pull sender out. yri
p by
co Vo
by lksw
cted
– Always renew O-ring.
agen
Prote AG.

Install in reverse order of removal.

– Tighten bolt to specified torque ⇒ Item 9 (page 193) .

50 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Driving speed sender -G68-

Location: driving speed sender is located top of gearbox on right.
Removing and installing driving speed sender
– Pull black connector off sender.
– Remove bolt and pull sender out.
– Always renew O-ring.
Install in reverse order of removal.
– Tighten bolt to specified torque ⇒ Item 20 (page 194) .

Selector lever lock solenoid -N110-

Location: the selector lever lock solenoid is located on the selec‐
tor lever -arrow-.
AG. Volkswagen AG d
Removing and installing selector lever lock solenoid lksw
agen oes
not
⇒ page 63 d by Vo gu
ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
Cruise control system switch -E45-
hole

spec
Location: cruise control switch is located on steering column
es, in part or in w

t to the co
switch.
Removing and installing cruise control system switch ⇒ Electrical
system; Rep. Gr. 94 ; Removing and installing steering column

rrectness of i
switch .
l purpos

Throttle valve potentiometer -G69- or accelerator pedal position

sender -G79-

nform
ercia

In vehicles with a data bus, the signal comes from the bus. In
m

addition, the data bus interface in these vehicles must be

a
com

tio
checked.

n in
r
te o

thi
If the electrical signals in the vehicle ⇒ self-diagnosis for gearbox

s
iva

do
electronics are displayed as faults, then ⇒ self-diagnosis for en‐
r
rp

cum
gine electronics must always be performed.
fo

en
ng

t.
yi Co
If the throttle valve potentiometer or accelerator pedal position Cop py
sender has been renewed or its setting changed, basic setting of
t. rig
gh ht
yri
the engine control unit must also be performed.
p by
co Vo
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cted agen
Locations:
Prote AG.

The potentiometer is a component part of the throttle valve mod‐

ule -J338- . It is located on the throttle valve housing on the
engine's intake manifold.
Checking and adjusting or removing and installing throttle valve
potentiometer ⇒ Rep. Gr. 24 .

3. Electrical and electronic components and their locations 51

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

The accelerator pedal position sender -G79- -arrow-, a compo‐

nent of the electronic power control (-EPC-), is located on the
pedal cluster.
Checking and adjusting or removing and installing accelerator
pedal position sender ⇒ Rep. Gr. 20 ; Removing and installing
parts of fuel supply system .

Kickdown switch -F8- in vehicles without EPC

Location: kickdown switch -arrow- is integrated into accelerator
cable and is located on bulkhead in engine compartment.
Removing and installing kickdown switch
– To remove and install kickdown switch, remove accelerator
cable then reinstall cable and adjust ⇒ Rep. Gr. 20 ; Assembly
overview - adjusting accelerator cable .

Kickdown switch -F8- in vehicles with EPC

Location: kickdown switch -arrow- is integrated in accelerator
pedal position sender.
Removing and installing kickdown switch
– Repairing accelerator mechanism ⇒ Rep. Gr. 20 ; Removing
and installing parts of fuel supply system .

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lkswage es n
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Starter inhibitor and reversing light relay -J226-
ce
e
nl

pt
du

an

Location: relay is located on the relay plate on left behind dash

itte

y li

panel.
erm

ab
ility
ot p

Relay is identified with number “175” -arrow-.

wit
, is n

h re

Removing and installing dash panel trim ⇒ General body repairs,

hole

spec

interior; Rep. Gr. 70 ; Dash panel; Removing and installing dash

es, in part or in w

panel .
t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by

52
co Vo
by lksw
Rep. Gr.37 - Controls, housing cted agen
Prote AG.
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Brake light switch -F- or brake pedal switch -F47-

Location: switch is located on the pedal cluster.
Removing and installing brake light switch or brake pedal switch
⇒ Brake systems; Rep. Gr. 46 ; Assembly overview - brake ped‐
al .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Electrical and electronic components and their locations 53

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4 Repairing selector mechanism

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

WARNING

Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.
AG. Volkswagen AG d
agen oes
olksw not
4.1 Checking selector mechanism ise
d by V gu
ara
nte
or eo
h
It should not be possible to operate the starter s a while the selector
ut ra
c
lever is in position “1”, “2”, “3”, “D” or “R”. s

ce
le
un

pt
On right-hand drive vehicles the starter must only operate in se‐

an
d
itte

y li
lector lever positions “P” and “N” when the locking button in the
erm

ab
selector lever handle is not pressed.

ility
ot p

wit
is n

When the vehicle is moving at speeds above 5 km/h and the se‐

h re
lector lever is shifted to position “N”, the solenoid for selector lever
ole,

spec
lock must not engage and block selector lever. Selector lever can
urposes, in part or in wh

be shifted into a driving gear.

t to the co
When the vehicle is moving at speeds below 5 km/h (almost sta‐
tionary) and the selector lever is shifted to position “N”, the sole‐ rrectne
noid for selector lever lock should only engage after about 1
second. Selector lever cannot be shifted out of “N” position until
brake pedal is depressed.
ss o
cial p

Selector lever in “P” position and ignition switched on:

inform
mer

• Brake pedal not depressed:

atio
om

Selector lever is locked and cannot be shifted out of “P” position

n
c

i
or

with the lock button pressed. Solenoid for selector lever lock
thi
te

blocks selector lever.

sd
iva

o
pr

cum
r

• Brake pedal depressed:

fo

en
ng

t.
yi Co
Solenoid for selector lever lock releases selector lever. It is pos‐ Cop py
t. rig
sible to shift into a driving gear. Slowly shift selector lever from yri
gh by
ht
“P” to “1”, checking whether selector lever position in dash panel cop Vo
by lksw
insert corresponds to selector lever position. cted agen
Prote AG.

Selector lever in “N” position and ignition switched on:

• Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal depressed:

54 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Solenoid for selector lever lock releases selector lever. It is pos‐

sible to shift into a driving gear.

4.2 Checking operation of the ignition key withdrawal lock

Start
↓
↓ ← ← ← ← ← ← ← ← ← ← ↑
↓ ↑
– Shift selector lever to “P”. Renew faulty selector mechanism or
steering lock.
– Switch off ignition. – Renew defective parts.
n AG. Volkswagen AG do
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– Pull out ignition key. Vol
ks ot g
d by ua
ran
↓ ris
e
↑ tee
tho or
↓ ss
au
no ac

ce
↓
le

↑
un

pt
an
d

Can selector lever be → y → Is locking cable in‐ → y → – Correct ad‐

itte

y li
erm

shifted out of “P” with e correctly adjusted? e justment

ab
ility
button pressed? s s ⇒ page 73 .
ot p

wit
is n

h re
ole,

↓ ↑

spec
urposes, in part or in wh

no ↑

t to the co
↓ ↑
– Depress brake pedal. ↑

rrectne
– Insert ignition key and switch on ignition.

– Shift selector lever to “P”. ss o

cial p

f in

↓ ↑
form
mer

Can selector lever be shifted out of → no → ↑

atio
m

“P” with button pressed?

o

n
c

i
or

n thi

↓ ↑
te

sd
iva

yes ↑
pr

cum
r
fo

en

↑
ng

↓ yi
t.
Co
op
– It must be possible to move selector lever ↑
C py
t. rig
gh
into “R, N, D, 3, 2, or 1”
ht
pyri by
Vo
co lksw
by
↓ ↑ Prote
cted AG.
agen

Can ignition key be withdrawn? → yes → ↑ ← ← ← ← ← no

↓ ↑
no → – Depress brake pedal. → The ignition key can be removed and
the button on the selector lever is
– Shift selector lever to “P”. blocked in “P”
↓
y
e
s
↓
⇒ Ignition key withdrawal lock
OK.

4. Repairing selector mechanism 55

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4.3 Removing and installing selector lever

handle
There are various handles which are removed and installed in
different ways.
. Volkswagen AG
gen AG does
– Before each installation job, push sleeve on selector lever
Vol
ksw
a
not
down somewhat. ed
by gu
ara
is nte
or
– Check colour of plastic part in handle -arrow-.auth eo
ra
ss c
Colour is black: removing and installing ⇒ page 56 .

ce
le
un

pt
an
d
Colour is red/brown: this handle can replace the handle with the
itte

y li
black plastic part. ⇒ page 56 . rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

4.3.1 Removing and installing handle with

red/brown plastic part

nform
ercia

– Simply pull handle only. Do not press button in process.

m

a
com

tio
If button is inadvertently pressed into handle, either pull it out

n in
r

again or carefully blow it out with compressed air.

te o

thi
s
iva

do
– It is essential to make sure before installing that the push but‐
r
rp

cum
ton is pulled out at least 10 mm -a- past the pressure point.
fo

en
ng

t.
yi Co
Do this by pulling the button out by hand past the palpable pres‐ Cop py
sure point so that it will not drop back again.
t. rig
gh ht
pyri by
Vo
o
– For installation, move selector lever to “D” and press handle
c by lksw
cted agen
onto selector lever.
Prote AG.

4.3.2 Removing and installing the handle with

the black plastic part
Removing
– Set selector lever in position “3”.

56 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Slide sleeve -1- downwards.

– Pull the button -2- out of handle -3- just enough that the pull
lever -arrow- hangs downwards.
– Now pull handle off selector lever.
Installing
– Set selector lever in position “3”.

– Pull the button -2- out of handle -3- just enough that the pull
lever -arrow- hangs downwards.
– Now press the handle on selector lever onto stop.
Installation position: Button faces driver.
– Pull button out slightly and guide pull lever -arrow- into handle.
– Press button so that pull lever engages in pull rod -4-.
The button must now spring back onto stop.
– Slide the sleeve -1- upwards.
– Set selector lever in position “P”.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un

pt
4.4 Dismantling and assembling shift mechanism an
d
itte

y li
rm

ab
pe

Lubricate bearing positions and sliding surfaces with polycarba‐

ility
ot

mide grease -G 052 142 A2- .

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by

57
cted agen
Prote AG.
4. Repairing selector mechanism
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Selector lever handle

❑ Removing and installing
⇒ page 56
❑ Allocation ⇒ Electronic
parts catalogue “ET‐
KA” .
2 - Sleeve
. Volkswagen AG
❑ Installation position:lkan‐ gen AG does
swa not
gled surface faces
d by V to‐
o gu
ara
wards back.orise nte
h eo
ut ra
3 - Cover ss
a c

ce
le

❑ With selector indicator

un

pt
an
d

❑ Removing and installing

itte

y li
erm

⇒ page 59

ab
ility
ot p

❑ Dismantling and assem‐

wit
is n

bling ⇒ page 60

h re
ole,

spec
4 - Printed circuit board
urposes, in part or in wh

❑ With wiring harness and

t to the co
LEDs for selector lever
illumination.

rrectne
❑ Removing and installing
⇒ page 60

s
❑ Cable routing
⇒ page 63 . s o
cial p

f inform

5 - Guide
mer

atio
m

❑ With cover strip.

o

n
c

i
or

❑ Removing and installing

thi
e

⇒ page 60
t

sd
iva

o
pr

❑ Dismantling and assem‐

um
r
fo

bling ⇒ page 60
en
ng

t.
yi Co
op py
6 - Spring t. C rig
gh ht
yri by
❑ For pull rod. cop Vo
by lksw
cted agen
Prote
7 - Pull rod
AG.

❑ Insert together with spring in selector lever.

❑ Removing and installing upper part of two-part pull rod ⇒ page 62 .
8 - Selector lever
9 - Detent plate
❑ Insert in selector lever together with spring retainer ⇒ Item 10 (page 58) .
10 - Spring retainer
❑ Insert both ends in selector lever.
11 - Nut, 10 Nm
12 - Mounting bracket
❑ Removing and installing ⇒ page 64
13 - Pivot pin
❑ Press out with screw driver.
14 - Pin
❑ For lever ⇒ Item 15 (page 58) to mounting bracket.
15 - Lever
❑ For locking cable

58 Rep. Gr.37 - Controls, housing

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Passat 1997 ➤
ris
ut
ho 4-speed automatic e o gearbox
ra
01N - Edition 10.2005
s a c
s
16 - Locking cable

ce
e
nl

pt
du

an
❑ For ⇒ ignition key removal lock.

itte

y li
erm

ab
❑ Must not be kinked.

ility
ot p

❑ Removing and installing ⇒ page 69

wit
, is n

h re
❑ Adjusting ⇒ page 73
hole

spec
17 - Securing clip
es, in part or in w

t to the co
❑ Always renew
18 - Securing spring

rrectness of i
❑ For locking cable
l purpos

❑ Clip into mounting bracket.

19 - Selector lever lock solenoid -N110-

nform
ercia

❑ Removing and installing ⇒ page 63

m

at
❑ Can be checked using “guided fault finding” of -VAS 5051- .
om

ion
c

in t
r

20 - Rubber housing
o

his
ate

❑ Must be separated only if damaged or to remove selector lever from mounting bracket

do
priv

c
⇒ Item 12 (page 58) .

um
for

en
ng

t.
yi
21 - Cover
Co
Cop py
.
❑ For mounting bracket.
ht rig
rig ht
py by
Vo
❑ Removing and installing ⇒ page 64
co lksw
by
cted agen
Prote AG.
22 - Securing clip
❑ For selector lever cable to selector lever.
❑ Always renew
23 - Locking plate
❑ For lever to mounting bracket.
❑ Always renew
24 - Selector lever cable
❑ Do not bend or kink; lightly grease cable eye and ball socket before installing.
❑ Rubber boot must not be damaged.
❑ Removing and installing ⇒ page 65
❑ Adjusting ⇒ page 68
25 - Support bracket
❑ For selector lever cable.
26 - Hexagon bolt, 23 Nm
27 - Ignition/starter switch

4.5 Removing and installing selector mech‐

anism cover
Additional required information
♦ Workshop manual Passat 1997 ▸ General body repairs, inte‐
rior

4.5.1 Removing
– Remove selector lever handle ⇒ page 56 .
– Pull pull rod up and hold up while moving selector lever to po‐
sition “P”.
– Switch off ignition.

4. Repairing selector mechanism 59

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove centre console ⇒ General body repairs, interior; Rep.

Gr. 68 ; Compartments, covers and trims .
– Carefully lever retaining tabs -arrows A- (Qty. 4) off from
above.
The four retaining tabs -arrows B- of the printed circuit board that
are visible from above must not be levered off. Otherwise, the
printed circuit board will be damaged.
Renew entire guide if retaining tabs -arrows A- are damaged.
If the retaining tabs -arrows B- are damaged, the cover must be
renewed together with the printed circuit board.
– Remove printed circuit board connector.
– Lift off complete cover of selector mechanism.
Dismantling and assembling selector mechanism cover
⇒ page 60 .

4.5.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Carefully place cover on selector mechanism and lock with
retaining tabs -arrows A- (Qty. 4).
Renew entire guide if retaining tabs -arrows A- are damaged.
olkswagen AG
en AG. V
If the retaining tabs -arrows B- are damaged, the coverksw must be
ag does
not
Vol
renewed together with the printed circuit board.
ed
by gu
ara
ris nte
– Connect printed circuit board connector.
au
tho eo
ra
ss c
– Install centre console ⇒ General body repairs, interior; Rep.
ce
e
nl

Gr. 68 ; Compartments, covers and trims .

pt
du

an
itte

– Install selector lever handle ⇒ page 56 . y li

erm

ab
ility
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wit
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h re

4.6 Dismantling and assembling selector

hole

spec

mechanism cover
es, in part or in w

t to the co

4.6.1 Dismantling
rrectness of i
l purpos

– Remove cover ⇒ page 59 .

The four retaining tabs -arrows B- of the printed circuit board must
nform
ercia

not be levered off. Otherwise, the printed circuit board will be

damaged.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Prote AG.

60 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Carefully lever off retaining tabs -arrows-.

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If retaining tabs are damaged, guide or cover with
olks
printed
wage circuit es n
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board must be renewed. d byV ua
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– Remove cover strip -2- from guide -3-.

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4.6.2 Assembling
– Check whether magnet -arrows- is attached to cover strip
-2-.
If not, renew cover strip.
– Insert cover strip -2- into guide -3-.

4. Repairing selector mechanism 61

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Carefully engage cover and guide -arrows-.

If retaining tabs are damaged, guide or cover with printed circuit
board must be renewed.
– Install cover ⇒ page 60 .

4.7 Removing and installing pull rod upper

part

4.7.1 Removing
– Remove selector lever handle ⇒ page 56 .
– Pull pull rod up -arrow 1- and hold up while moving selector
lever to position “P”. gen AG
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d a oes
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– Use a driver to push db
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part -arrow 2-. orise nte
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– Leave driver
ss inserted in pull rod lower part.
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4.7.2 Installing
– If pull rod upper part is renewed, if necessary, pull up of pull
rrectne

rod lower part using long-nose pliers -arrow 1-.

– Insert driver into location hole for pull rod upper part
ss

-arrow 2-.
o
cial p

f in

– Pull up on pull rod and hold up while moving selector lever to

form
mer

position “2”.
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62 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Pull lower part of pull rod up to stop -arrow 1- with drift and
hold it.
– Push upper part into lower part -arrow 2-.

– Then press pull rod upper part into pull rod lower part to stop
-arrows-, applying drift above and below.
Tension spring must then be able to pull entire pull rod up to stop
in selector mechanism.
– Install selector lever handle ⇒ page 56 .
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4.8 Removing and installing selector lever

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ility
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lock solenoid -N110- and wiring for se‐

wit
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lector lever illumination

hole

spec
es, in part or in w

– Remove selector lever handle ⇒ page 56 .

t to the co

– Remove cover ⇒ page 59 .

rrectness of i

– Remove centre console and extension ⇒ General body re‐

pairs, interior; Rep. Gr. 68 ; Compartments, covers and trims .
l purpos

– Separate connector -1- (console wiring harness).

nform
ercia

– Using a screwdriver, press metal tab on lower side of lifting

magnet-2- inwards while turning lifting magnet about 90° in
m

direction of arrow.
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tion in
r

– Pull out lifting magnet.

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thi
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– After renewing magnet, check selector mechanism

r
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cum

⇒ page 54 .
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– Route wiring for selector lever illumination under guide -3- and
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– Clip connector -5- into retainer on guide.
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4. Repairing selector mechanism 63

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Join connector -1- (console wiring harness).

– Install centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
– Install cover ⇒ page 60 .
– Install selector lever handle ⇒ page 56 .

4.9 Removing and installing selector mech‐

anism

4.9.1 Removing
– Move selector lever to “P” position.
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– With ignition switched off, disconnect battery earth strap.
– Remove selector lever handle ⇒ page 56 .
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims .
– Raise vehicle.
– Remove catalytic converter or front exhaust pipe ⇒ Rep. Gr.
26 ; Removing and installing parts of exhaust system. .
– Release snap fasteners of cover -1- by pressing in direction of
-arrow A-.
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– Remove cover from mounting bracket -2-. olksw
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– Separate selector lever cable -3- from mounting bracket
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– Press together ends of securing clip -4- and remove.
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– Pull selector lever cable off selector lever -5-.

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– Pull down locking plate -6- for securing selector lever cable to
pe

ility
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mounting bracket and remove.

wit
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– Pull selector lever cable out from mounting bracket without

hole

spec

kinking cable.
es, in part or in w

t to the co

– Remove cover with guide ⇒ page 59 .

– Unclip locking cable from securing spring on mounting bracket
rrectness of i

by lifting securing spring slightly.

l purpos

– Unclip connector for selector lever lock solenoid and selector

lever illumination ⇒ page 63 .
nform
ercia

– Remove nuts -7- (Qty. 4).

m

– Remove mounting bracket -2- downwards.

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tion in
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4.9.2 Installing
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Install in reverse order of removal. During this step, observe the

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following:
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Rep. Gr.37 - Controls, housing Prote AG.
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
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– Do not bend or kink selector leverbycable.
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Lightly grease cable not gua
eye and ball socket before installing.
ris
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– Always renew securing clip
ss
au
-4- and locking plate -6-. ac

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le
– When renewing mounting bracket, join rubber housing -8- to

un

pt
an
mounting bracket before installing.

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– Ensure perfect seal between mounting bracket and body.

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– Tighten nuts -7- (Qty. 4) ⇒ Item 11 (page 58) .
is n

h re
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– Install and adjust locking cable ⇒ page 72 .

spec
urposes, in part or in wh

– Guide cover into groove -9- and lock snap fastener. Ensure

t to the co
perfect seating and seal of cover.
– Install selector lever handle ⇒ page 56 .

rrectne
– Check selector lever cable adjustment and adjust if necessary
⇒ page 68 .

ss o
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f
– Check ignition key withdrawal lock ⇒ page 55 .

inform
mer

– Install centre console ⇒ General body repairs, interior; Rep.

atio
Gr. 68 ; Compartments, covers and trims .
om

n
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– Install catalytic converter or front exhaust pipe ⇒ Rep. Gr. 26 ;

thi
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Removing and installing parts of exhaust system. .
iva

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– On vehicles with coded radio, activate radio code ⇒ Radio,

fo

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telephone, navigation; Rep. Gr. 91 ; Radio systems .

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– Initialise electric windows and set clock ⇒ Maintenance ; Book‐
t
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4.10 Removing and installing selector lever

cable

4.10.1 Removing
– Move selector lever to “P” position.
– Raise vehicle.
– Unfasten front heat shield above exhaust pipe and push it
back.
– Release snap fasteners of cover -1- by pressing in direction of
-arrow A-.
– Remove cover from mounting bracket -2-.
– Separate selector lever cable -3- from mounting bracket as
follows:
– Press together ends of securing clip -4- and remove.
– Pull selector lever cable off selector lever -5-.
– Pull down locking plate -6- for securing selector lever cable to
mounting bracket and remove.
– Do not kink selector lever cable.

4. Repairing selector mechanism 65

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove noise insulation tray -arrows-.

– Remove bolts -2- and -3-.

– Remove shield -1- for selectorAlever
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– Pull selector lever cable -1- upwards off selector shaft lever
t to the co

-2-.
– Remove cable support bracket -3- from right gearbox support.
rrectne

– Release selector lever cable from support bracket -4-.

ss o
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mer

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4.10.2 Installing
• Selector lever and selector shaft lever in position “P” (⇒ park‐
ing lock must engage).
Install in reverse order of removal. During this step, observe the
following:
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
tion).

66 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Always renew securing clip -4- and locking plate -6-.

– Do not bend or kink selector lever cable. Lightly grease cable
eye and ball socket before installing.
– Connect support bracket -3- with selector lever cable.
– Bolt support bracket to right gearbox support and tighten
⇒ Item 26 (page 59) hexagonagbolt.
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t to the co
– Install selector lever cable shield -1- and tighten bolts -2- and
-3- ⇒ page 67 .

rrectness o
cial p

f inform
mer

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– Install noise insulation -arrows-. gh ht
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– Check and adjust selector lever cable ⇒ page 68 . Prote
cted AG.
agen

4.10.3 Torque settings

Bolts -2- M6 10 Nm
Bolts -3- M10 23 Nm

4. Repairing selector mechanism 67

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4.11 Checking and adjusting selector lever

cable

4.11.1 Checking
– Move selector lever to “P” position.
– Remove noise insulation tray -arrows-.

– Remove bolts -2- and -3-.

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– Remove shield -1- for selector lever cable.Volkswag does
not
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t to the co
– Pull selector lever cable -1- upwards off selector shaft lever
-2-.
rrectness of i

– Put down selector lever cable so its end can move freely.
– Move selector lever from “P” to “1”.
l purpos

• Selector lever mechanism and selector lever cable must move

nform
ercia

freely. If necessary, renew selector lever cable or repair se‐

lector lever mechanism.
m

at
om

io

– Move selector lever to “P” position.

n
c

in t
or

his
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– Move selector shaft lever on gearbox to position “P”. Locking

at

do
riv

lever must engage in parking lock wheel so that both front

p

cum

wheels are blocked (cannot be turned together in same direc‐

for

en
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tion).
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shaft lever. Adjust selector lever cable if necessary.
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4.11.2 Adjusting
• Selector lever cable is disconnected from selector shaft lever.
– Move selector lever to “P” position.
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in parking lock wheel so that both front

68 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

wheels are blocked (cannot be turned together in same direc‐

tion).
– Loosen securing bolt on support bracket -3-.
– Press selector lever cable -1- onto selector shaft lever -2-.
– Align selector lever cable on support bracket free of tension.
– Tighten securing bolt for support bracket
⇒ Item 26 (page 59) hexagon bolt.

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– Install selector lever cable shield -1- and tighten bolts -2- and

wit
is n

-3- ⇒ page 67 .

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

– Install noise insulation -arrows-.

i
or

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te

sd
a

– Check selector mechanism ⇒ page 54 .

iv

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4.12 Removing, installing and adjusting lock‐

ing cable
Special tools and workshop equipment required

4. Repairing selector mechanism 69

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Setting gauge for locking cable -3352 A-

4.12.1 Removing locking cable

– For vehicles with coded radio unit, note or obtain code.
– With ignition switched off, disconnect battery earth strap.
– Remove selector lever handle ⇒ page 56 .
– Remove centre console and extension ⇒ General body re‐
pairs, interior; Rep. Gr. 68 ; Compartments, covers and trims .
– Remove steering wheel with airbag ⇒ General body repairs,
interior; Rep. Gr. 69 ; Airbag; Removing and installing driver
side airbag unit and ⇒ General body repairs, interior; Rep. Gr.
69 ; Airbag; Removing and installing steering wheel .
– Remove return ring with slip ring ⇒ General body, interior;
Rep. Gr. 69 ; Airbag; Removing and installing return ring with
slip ring .
– Remove steering column switch ⇒ Electrical system; Rep. Gr.
94 ; Removing and installing steering column switch .
– Turn ignition key to ignition on position.
AG. Volkswagen AG d
– Move selector lever to “P” position. lksw
agen oes
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rrectness of i
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te o

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Prote AG.

70 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

AG. Volkswagen AG d
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un

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pe

ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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a
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tion in
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te o

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– Lift retaining clip on locking device -1- and pull locking cable
out from ignition/starter switch.
– Remove cover with guide (selector lever mechanism)
⇒ page 57 .
– Unclip locking cable from securing spring on mounting bracket
by lifting securing spring slightly.
– Release locking cable from cable tie -2- and take out.

4. Repairing selector mechanism 71

 olkswagen AG
Passat 1997 ➤ wage
n AG. V does
olks not
4-speed automatic gearbox 01N - Edition 10.2005
db
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ara
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ris
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4.12.2 Installing locking cable ss
au ra
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un

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an
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es, in part or in w

t to the co
rrectness of i
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nform
mercia

a
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tion in
r
te o

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– Route locking cable free of kinks.

– Turn ignition key to ignition on position.
– Fit locking cable to ignition/starter switch.
– Check that locking device -1- engages.
– Secure locking cable with cable tie -2-.
– Turn ignition/starter switch to locked position (ignition off).
– Move selector lever to “P” position.
– Clip locking cable onto securing spring in mounting bracket.
– Hook locking cable support bracket -3- into selector mecha‐
nism and locking cable eye into lever (for locking cable).

72 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

4.12.3 Adjusting locking cable swagen AG. Volkswagen AG does

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ility
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es, in part or in w

t to the co
rrectness of i
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mercia

at
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ion
c

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or

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ate

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– Loosen bolt -6-.

– It must be possible to move support bracket -3- by hand in
direction of arrow -5-.
– Move steering column down.
– Push on locking cable adjustment gauge -3352 A- -4- between
lever for locking cable and locking cable eye.
– Pull locking cable in direction of arrow -5- and tighten bolt -6-
to 10 Nm.
– Remove adjustment gauge.
– Check ⇒ ignition key withdrawal lock after each adjustment of
locking cable ⇒ page 55 .
– Install steering column switch ⇒ Electrical system; Rep. Gr.
94 ; Removing and installing steering column switch .
– Install return ring with slip ring and steering column switch trim
⇒ General body, interior; Rep. Gr. 69 ; Airbag; Removing and
installing return ring with slip ring .
– Install steering wheel with airbag ⇒ General body repairs, in‐
terior; Rep. Gr. 69 ; Airbag; Removing and installing steering

4. Repairing selector mechanism 73

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

wheel and ⇒ General body repairs, interior; Rep. Gr. 69 ;

Airbag; Removing and installing driver side airbag unit .
– Remove centre console and extension ⇒ General body re‐
pairs, interior; Rep. Gr. 68 ; Compartments, covers and trims .
– Install selector lever handle ⇒ page 56 .
– Connect earth strap to battery.
– On vehicles with coded radio, activate radio code ⇒ Radio,
telephone, navigation; Rep. Gr. 91 ; Radio systems .
– Initialise electric windows and set clock ⇒ Maintenance ; Book‐
let 36 .

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es, in part or in w

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Prote AG.

74 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

5 Measuring main pressure

Inferences about the “hydraulic system” of the gearbox may be
made based on the main pressure measurement.
♦ The output of the ATF pump can be checked.
♦ It can be checked whether the valve body is jammed or catch‐
es or exhibits excessive leakage.

Special tools and workshop

equipment required
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Automatic gearbox tester -
V.A.G 1702-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
♦ Diagnosis wiring -
VAS 5051/3-

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Test conditions
rm
m

atio
m

• No faults stored in memory of automatic gearbox control unit

o

n in
c

-J217- ; do not disconnect tester!

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• ⇒ ATF level OK
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5. Measuring main pressure 75

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

If possible, check the main pressure on a rolling road dynamom‐

eter.

– Remove noise insulation tray -arrows-.

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is n

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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
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Prote AG.

76 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove bolt -arrow- for main pressure hole; always renew

bolt.
– Connect automatic gearbox tester -V.A.G 1702- and tighten
knurled screw.
– Ensure that knurled screw is tight.
– Start engine.
– Bleed automatic gearbox tester -V.A.G 1702- by unscrewing
knurled screw. Tighten screw again after bleeding.
The manometer is bled when a drop of ⇒ ATF escapes.
– Press guided functions . AG. Volkswagen AG d
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– Identify vehicle. by Vo gu
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d
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– Select Automatic gearbox
uthor
01N eo
a ra
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– s
Read measured value - gearbox control unit

ce
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pt
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– Bring ⇒ ATF temperature to 60° C.

itte

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Main pressure specifications at idling speed

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is n

Selector lever positions

h re
ole,

D R

spec
urposes, in part or in wh

Idling Idling

t to the co
Main pressure in bar 3.4…3.8 5…6

rrectne
Deviations from specifications may be due to the following cau‐
ses:

ss
Possible causes Remedy

o
cial p

f in
Idling speed too high Adjust engine

form
mer

⇒ ATF pump defective Check ⇒ ATF pump and renew atio

m

if necessary
o

n
c

i
or

Valves stuck in ⇒ valve body Renew ⇒ valve body.

thi
te

sd
iva

o
pr

– Switch off engine.

um
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Prote AG.

5. Measuring main pressure 77

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Connector for solenoid valves ⇒ arrow -arrow-

– Press locking device together and pull off connector.
– Start engine.
Main pressure specifications at 2000 rpm
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gen AG d
Selector lever olks positions and measurings not g
wa oe
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ris tee
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D R or
a ac
ssEngine speed ap‐ Engine speed ap‐

ce
e

prox. 2000 rpm prox. 2000 rpm

nl

pt
du

an
itte

Main pressure in bar 12.4…13.2 23.0…24.0

y li
erm

ab
ility
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Deviations from specifications may be due to the following cau‐

wit
ses:
, is n

h re
hole

spec
Possible causes Remedy
es, in part or in w

t to the co
⇒ ATF pump defective Check ⇒ ATF pump and renew
if necessary
Valves stuck in ⇒ valve body Renew ⇒ valve body.

rrectness of i
After the measurement:
l purpos

– Remove automatic gearbox tester -V.A.G 1702- .

nform
ercia

– Install new bolt for main pressure hole and tighten to 12 Nm.
m

at
om

io
– Push on connector for ⇒ solenoid valves -arrow-.
n
c

in t
or

his
e

– After joining connector, read and then erase fault memory.

at

do
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– Install noise insulation -arrows-.

78 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6 Removing and installing gearbox

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Special tools and workshop by Vo gu
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equipment required rise
d
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♦ Support bracket -10 - 222 ss a ra
c
A-

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♦ Rack -10 - 222 A /1-

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ab
♦ Adapter -10 - 222 A/3-

ility
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wit
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♦ Gearbox support -3282-

h re
♦ Adjustment plate -3282/3- hole

spec
es, in part or in w

t to the co
♦ Gearbox mounting support
-3336-

rrectness of i
l purpos

nf
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orm
m

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Prote AG.

6. Removing and installing gearbox 79

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Support bridge -30 - 211 A-

♦ Hose clamps to 25 mm Ø
-3094-
♦ Workshop hoist - agen
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V.A.G 1202 A- olksw not
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♦ Drip tray -V.A.G 1306- horis nte
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♦ Torque wrench -V.A.G ss c
1331-

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♦ Torque wrench -V.A.G

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ab
1332-

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

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mer

atio
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c

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80 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Engine and gearbox jack -

V.A.G 1383 A-
♦ Hose clamp pliers -V.A.G
1921- n AG. Volkswagen AG do
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♦ Vehicle diagnosis, testing byV
o ot g
ua
and information system - ir se
d ran
tee
VAS 5051- autho
or
ac
ss
♦ 15 mm socket, Matra -V/

ce
e
nl
175-

pt
du

an
itte

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erm

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ility
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spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
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Additional required information

♦ Workshop manual Passat 1997 ▸ Running gear, axles, steer‐
ing front and four-wheel drive
♦ Workshop manual Passat 1997 ▸ Electrical system
♦ Workshop manual Passat 1997 ▸ Engine

6.1 Removing gearbox

– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Move selector lever to “P” position.
– With ignition switched off, disconnect battery earth strap.

6. Removing and installing gearbox 81

 Passat 1997 ➤
n AG. Volkswagen AG do
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4-speed automatic gearbox 01Nolk-sEdition 10.2005 es n
V o t gu
by ara
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– Remove cover from engine. thoris
eo
au ra
– Assemble adapter -10 - 222
ss A/3- for front spindle on support c

ce
e
bar.

nl

pt
du

an
itte
– Fit support device -10 - 222 A- with legs -10 - 222 A /1- and

y li
erm

ab
support engine with gearbox in this position.

ility
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wit
– Remove front wheels.
, is n

h re
hole

– Raise vehicle.

spec
es, in part or in w

t to the co
rrectness of i
– Remove noise insulation tray -arrows-.
l purpos

– Remove noise insulation retainer.

nf
ercia

orm
m

atio
om

n in
or c

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te

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– Mark connections -arrows C- and -D- for reinstallation. Prote AG.

– Remove electrical connections -arrows A- through -D- at gear‐

box.
– Remove wiring harness clamp -arrow E-.
Vehicles with TDI engine

– Remove left and right drive shaft noise insulation from wheel
housing -arrows-.
Continuation for all vehicles

82 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Pull connector off speed sender -G68- on gearbox.

– Remove front exhaust system with catalytic converter ⇒ Rep.
Gr. 26 ; Removing and installing parts of exhaust system .

– Remove left drive shaft guard plate -arrows-. The third bolt is
not visible in the figure.
– Disconnect left and right drive shafts -1- from flanges and tie
up.

– Remove bolts -2- and -3-.

– Remove shield -1- for selector lever cable.

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V gu
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– Remove bolts -1-.

y li
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ab
ility

– Remove heat shield -2-.

ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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o
pr

cum
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fo

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t.
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Prote AG.

6. Removing and installing gearbox 83

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Unscrew bolt -2-.

– Pull ⇒ ATF lines -A- and -B- off gearbox and tie up with wire.

AG. Volkswagen AG d
agen oes
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ce
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nl

pt
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an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter -
hole

spec
B- .
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
te

– Remove nuts (Qty. 3) from torque converter with 15 mm sock‐

a

do
riv

et, Matra -V/175- . Turn crankshaft 1/3 turn for each bolt.
p

cum
for

en
ng

– Remove lower engine/gearbox connecting bolts.

t.
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Prote AG.

– Set up gearbox support -3282- .

Set up gearbox support -3282- for automatic gearbox 01N with
adjusting plate -3282/3- .
The symbols on the adjusting plate indicate the mounts required;
the arrow points forward.

84 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Move engine and gearbox jack -V.A.G 1383 A- with gearbox

support -3282- under vehicle, align adjusting plate parallel to
gearbox and support gearbox.

– Pull selector lever cable -1- upwards off selector shaft lever
-2-. G. Volkswagen
a o gen A AG d
– Mark position of support bracket lkswon gearbox support fores not
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reinstallation. ris
ed
b ara
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– Remove support bracket
s a -3- from gearbox support.
u ac
s

ce
e

– Release selector lever cable from support bracket -4-.

nl

pt
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an
itte

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erm

ab
ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Remove right gearbox support -arrow- with bonded rubber or

mounting.
m
m

atio
m

– Remove left bonded rubber mounting.

o

n in
or c

thi
e

– Lower rear of engine/gearbox assembly slightly with engine

t

sd
iva

and gearbox jack -V.A.G 1383 A- .

o
r
rp

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Prote AG.

6. Removing and installing gearbox 85

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove upper engine/gearbox connecting bolts -arrows-.

– Press gearbox off engine while simultaneously pressing ⇒ tor‐
que converter out of drive plate.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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ce
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– Press ⇒ torque converter against ⇒ ATF pump -arrow-.

un

pt
an
d
itte

y li
– Lower gearbox.
rm

ab
pe

ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Secure ⇒ torque converter to prevent it from falling out.

nform
ercia

Transporting gearbox ⇒ page 91

m

a
com

tio

Securing gearbox to assembly stand ⇒ page 92

n in
r
te o

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6.2 Installing gearbox

Install in reverse order of removal. But first carry out the following
additional work:
– Before installing gearbox, clean ⇒ ATF lines and ⇒ ATF cooler
⇒ page 111 .
– Before installing gearbox, ensure that dowel sleeves between
the engine and gearbox are correctly located ⇒ page 91 .
– Ensure that intermediate plate is correctly seated on engine.
– Before installing gearbox, ensure that ⇒ torque converter is
correctly seated in gearbox ⇒ page 42 .
The torque converter must not slip from its proper position when
gearbox is brought into position.

86 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Set up gearbox support -3282- .

Set up gearbox support -3282- for automatic gearbox 01N with
adjusting plate -3282/3- .
The symbols on the adjusting plate indicate the mounts required;
the arrow points forward.
– Place gearbox on gearbox jack.
AG. Volkswagen AG d
agen oes
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y V gu
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rise nte
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au ra
ss c

ce
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un

pt
– Lock safety support -arrow- to gearbox.

an
d
itte

y li
erm

ab
– Place gearbox jack under vehicle.

ility
ot p

– Align gearbox to engine.

wit
is n

h re
ole,

– Before tightening bolts, check whether the removed bolts must

spec
urposes, in part or in wh

be renewed. Particularly bolts which are not directly installed

t to the co
in the gearbox must often be replaced with new ones.
Bolts for the subframe and wheel suspension are frequently af‐
fected. Refer to the respective repair groups.

rrectne
– An additional retainer or line may be secured with a nut to
some bolts ⇒ page 91 (torque settings).

ss o
cial p

f
– Install upper engine/gearbox connecting bolts.

inform
mer

– Raise rear of engine/gearbox assembly slightly with engine

atio
m

and gearbox jack -V.A.G 1383 A- .

o

n
c

i
or

n
– Install left bonded rubber mounting ⇒ page 94 .

thi
te

sd
iva

o
pr

cum
– Install right gearbox support -arrow- with bonded rubber
r
fo

en
ng

mounting and tighten bolts ⇒ page 94 .

t.
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Cop py
– Install lower engine/gearbox connecting bolts.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6. Removing and installing gearbox 87

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Tighten nuts for ⇒ torque converter with 15 mm socket, Matra

-V/175- . Turn crankshaft 1/3 turn for each bolt.
– Install starter ⇒ Electrical system; Rep. Gr. 27 ; Starter -B- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
– Always renew O-rings -1-.
hole

spec
es, in part or in w

– Moisten O-rings with ⇒ ATF.

t to the co
– Ensure that O-rings are seated correctly so that they do not
slip from their seats -A- and -B- when ⇒ ATF lines are inserted.

rrectness of i
– Insert ⇒ ATF lines completely to stop in gearbox by hand.
l purpos

– Do not tighten bolt -2- until all ⇒ ATF lines have been com‐
pletely inserted ⇒ page 107 .

nform
mercia

at
om

ion
c

in t
or

his
ate

– Attach right shield -2- to gearbox and tighten bolts -1- do

priv

c
⇒ page 99 .
um
for

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Prote AG.

– Install selector lever cable shield -1- and tighten bolts -2- and
-3- ⇒ page 67 .

88 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Attach drive shafts -1- to flange shafts ⇒ Running gear, axles,

steering - front and four-wheel drive; Rep. Gr. 40 ; Repairing
drive shafts; Removing and installing drive shafts .
– Install right drive shaft guard plate -arrows-. Third bolt cannot
be seen in figure ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
Vehicles with TDI engine

n AG. Volkswagen AG do
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o ot g
byV ua
d ran
ir se
– Install left and right drive shaft noisetho insulation in wheel hous‐ tee
or
ing -arrows-. au ac
ss

ce
e

Continuation for all vehicles

nl

pt
du

an
itte

– Install front exhaust system with catalytic converter ⇒ Rep.

y li
erm

ab
Gr. 26 ; Removing and installing parts of exhaust system .

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– Attach electrical connections -arrows A- through -D- at gear‐
l purpos

box.
Do not interchange electrical connections -arrows C- and -D-.

nform
ercia

Connection -arrow C- goes to driving speed sender -G68- (right

m

at
side of gearbox).
om

ion
c

in t
r

Connection -arrow D- goes to gearbox speed sender -G38- (left

o

his
te

side of gearbox).
a

do
priv

cum
or

– Install wiring harness clamp -arrow E-.

f

en
ng

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Cop py
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by
cted agen
– Push connector onto driving speed sender -G68- . Prote AG.

– Install noise insulation retainer ⇒ General body repairs, exte‐

rior; Rep. Gr. 50 ; Noise insulation .

6. Removing and installing gearbox 89

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install noise insulation -arrows-.

– Install front wheels ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 44 ; Installing wheels and tyres:
Installing wheel .
– Remove support device -10 - 222 A- .
– Install engine cover.
– Connect earth strap to battery.
After installation: perform basic setting ⇒ page 45 .
– On vehicles with coded radio, activate radio code ⇒ Radio,
telephone, navigation; Rep. Gr. 91 ; Radio systems .
– Initialise electric windows and set clock ⇒ Maintenance ; Book‐
let 36 .
– Move selector lever to position “P” and push selector lever ca‐
ble onto selector shaft lever.

– Tighten bolt -3- for selector cable support bracket according

to marking on gearbox -arrows- ⇒ Item 26 (page 59) hexagon
bolt.
– Check selector lever cable adjustment and adjust if necessary
⇒ page 68 .
– With gearbox installed, check gear oil level in final drive
⇒ page 198 .
AG. Volkswagen AG d
– Then check ⇒ ATF level and top up ⇒ page 100 . ksw
agen oes
not
Vol
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itte

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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– When checking ⇒ ATF level, check ⇒ ATF line connections
-A- and -B- for leaks.

rrectne
– Carry out ⇒ self-diagnosis and initiate basic setting
⇒ page 45 .
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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cum
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Prote AG.

90 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.2.1 Torque settings

Vehicles with 4-cylinder engine, engine codes AHL, ANA and n AG. Volkswagen AG do
ARM only olks
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Gearbox to engine db ara
rise nte
tho eo
Item Bolt Quantity au Nm
ra
c
ss

ce
e
1 M 12 x 75 1 65

nl

pt
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an
itte
2 M 12 x 90 1 65

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erm

ab
with wiring harness

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retainer

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3 M 12 x 90 1 65

h re
hole

spec
4 M 10 x 45 1 45
with hexagon nut es, in part or in w

t to the co
5 M 10 x 45 3 45
6 M 12 x 90 1 65

rrectness of i
7 M 12 x 67 2 65
l purpos

8 M 12 x 75 1 65
with wiring harness
retainer

nform
ercia

Item -A- = dowel sleeves

m

at
om

ion
c

in t
or

Vehicles with 4-cylinder engine, engine codes except AHL, ANA

his
te

and ARM
a

do
priv

cum
or

Gearbox to engine
f

en
ng

t.
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op
Item Bolt Quantity Nm C py
ht. rig
rig ht
by
1 M 12 x 67 2 65 copy Vo
by lksw
cted agen
2 M 12 x 90 2 Prote 65 AG.

3 M 12 x 67 1 65
4 M 12 x 67 1 65
5 M 12 x 67 1 65
6 M 10 x 45 3 45
7 M 10 x 45 1 45
with hexagon nut
Item -A- = dowel sleeves
Continuation for all vehicles
Torque converter to drive plate 85 Nm
Connecting ⇒ ATF lines ⇒ page 107
Shield to right bonded rubber mounting on gear‐ 10 Nm
box

6.3 Transporting automatic gearbox

Special tools and workshop equipment required

6. Removing and installing gearbox 91

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Gearbox mounting support -3336-

♦ Workshop hoist -V.A.G 1202 A-

n AG. Volkswagen AG do
lkswage es n
o ot g
Use gearbox lifting tackle -3336- by V to transport automatic gearbox ua
ed ran
as well as to set up gearboxoris support -3282- . tee
th or
u
– Secure gearbox lifting
ss
a
tackle -3336- to gearbox housing ac
flange.
ce
e
nl

pt
du

an

– Position locking pins so that 12 holes are visible in chain di‐

itte

y li
erm

rection.
ab
ility
ot p

– Lift gearbox with workshop hoist -V.A.G 1202 A- and gearbox

wit
, is n

lifting tackle -3336- .

h re
hole

spec

Securing gearbox to assembly stand ⇒ page 92

es, in part or in w

t to the co
rrectness of i
l purpos

6.4 Securing gearbox to assembly stand

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

92 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Workshop hoist -
V.A.G 1202 A-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
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e
nl

pt
du

an
itte

y li
erm

ab

– Secure gearbox lifting tackle -3336- to gearbox housing

ility
ot p

flange.
wit
, is n

h re

– Position locking pins so that 8 holes are visible in chain direc‐

hole

spec

tion.
es, in part or in w

t to the co

– Place drip tray -V.A.G 1306- underneath.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

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priv

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for

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ng

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Prote AG.

6. Removing and installing gearbox 93

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove plug -1- and ⇒ ATF overflow pipe -2-.

– Drain ⇒ ATF.
3 - Plug
4 - Cap
– Take out ⇒ torque converter.
– Using workshop hoist -VW 309- , attach gearbox with support
plate -V.A.G 1202 A- to support clamp -VW 313- .

– Secure gearbox to assembly support with bolts -1- and -2- -

M10- .

AG. Volkswagen AG d
agen oes
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6.5 Removing and installing left and right gearbox support by gu
d ara
rise nte
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nl

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du

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erm

ab
ility
ot p

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hole

spec
es, in part or in w

t to the co
rrectness of i
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orm
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Prote AG.

94 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
AG. Volkswagen AG d
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Special tools and workshop byV
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♦ Gearbox support -3282- ss a ra
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♦ Adjustment plate -3282/3-

un

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♦ Torque wrench -
erm

ab
V.A.G 1331-

ility
ot p

wit
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♦ Engine and gearbox jack -

h re
V.A.G 1383 A-
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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te

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Prote AG.

6.5.1 Removing
If both gearbox mountings are to be removed, the gearbox must
be supported as described. If only one gearbox support is to be
removed, the support is not necessary.
– Set up gearbox support -3282- .
Set up gearbox support -3282- for automatic gearbox 01N with
adjusting plate -3282/3- .
The symbols on the adjusting plate indicate the mounts required;
the arrow points forward.

6. Removing and installing gearbox 95

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Move engine and gearbox jack -V.A.G 1383 A- with gearbox

support -3282- under vehicle, align adjusting plate parallel to
gearbox and support gearbox.
– Lock safety support -arrow- to gearbox.

6.5.2 Removing left gearbox support swage

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Vehicles with TDI engine d b ua
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– Remove left drive shaft noise insulation from wheel
au housing
t or
ac
-arrows-. ss

ce
le
un

pt
Continuation for all vehicles

an
d
itte

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erm

ab
ility
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wit
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ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Separate gearbox support -2- by removing bolts -1- from gear‐

ss
box.

o
cial p

f in
Left gearbox support

form
mer

atio
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– Unscrew bolts -6-.
– Remove gearbox support -2-.
With hydraulic gearbox mounting -8-, there is no item -4- or -5-
because bolt -7- is screwed directly into gearbox mounting.

96 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6.5.3 Installing left gearbox support

Install in reverse order of removal.
Torque settings
Left gearbox mounting
Bolt -6- 27 Nm
Bolt -1- with hexagon nut -5- 50 Nm
Bolt -7- 50 Nm

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Left gearbox support

ility
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Bolt -1- 40 Nm

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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orm
m

atio
m

6.5.4 Removing right gearbox support

o

n in
or c

thi
e

Vehicles with TDI engine

t

sd
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o
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cu

– Remove right drive shaft noise insulation from wheel housing

o

m
f

en
ng

-arrows-.
t.
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Cop py
Continuation for all vehicles
t. rig
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by
cted agen
Prote AG.

6. Removing and installing gearbox 97

 AG. Volkswagen AG d
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Passat 1997 ➤ ed b ara
nte
ris
4-speed automatic gearbox 01N - Edition 10.2005
ut
ho eo
ra
s a c
s
– Remove left drive shaft guard plate -arrows-. The third bolt is

ce
le
un

pt
not visible in the figure.

an
d
itte

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erm

ab
ility
ot p

wit
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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
– Remove bolts -1-.
cial p

f inform
– Remove heat shield -2-.
mer

atio
m

– Separate gearbox support -5- by removing bolts -3- and -4-

o

n
c

i
from gearbox.
or

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sd
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Right-hand gearbox support

iv

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Prote AG.

– Unscrew bolts -7-.

– Remove gearbox support -2-.
With hydraulic gearbox mounting -9-, there is no item -5- or -6-
because bolt -8- is screwed directly into gearbox mounting.

6.5.5 Install right gearbox support

Install in reverse order of removal.

98 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Torque settings
Right gearbox mounting
Bolt -7- 27 Nm
AG. Volkswagen AG d
Bolt -1- with hexagon nut -6- agen 50 Nm oes
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Bolt -8- d b 50 Nm ara
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Right-hand gearbox support

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o
Bolt -1- 10 Nm

rm
m

atio
Bolt -3- M 10 x 30 mm 50 Nm
om

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c

Bolt -4- M 10 x 70 mm 40 Nm
or

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Prote AG.

6. Removing and installing gearbox 99

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

7 Checking ⇒ ATF level and topping up

Observe these notes as well.
♦ About this workshop manual ⇒ page 1
♦ About ATF ⇒ page 13
♦ About “filler pipe” ⇒ page 12

Special tools and workshop

equipment required
♦ drip tray -V.A.G 1306- if no
used oil collection and ex‐
traction unit -V.A.G 1782- is
available
♦ Use adapter for oil filling -
VAS 6262- with -VAS n AG. Volkswagen AG do
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♦ Vehicle diagnosis, testinghoris tee
and information systemau -
t or
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VAS 5051- can also bess
ce
e

used
nl

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spec
es, in part or in w

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rrectness of i
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nform
mercia

at
om

ion
c

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or

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ate

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priv

cum
for

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Prote AG.

100 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

If ATF must be added, use ATF as a replacement part.

– If ATF level is checked, oil seal -arrow- on ATF inspection plug gen AG. Volkswagen AG d
must always be renewed. Vol
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ility
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spec
urposes, in part or in wh

t to the co
7.1 Checking ⇒ ATF level

rrectne
– Switch off engine.

ss o
cial p

f inform
mer

atio
om

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Prote AG.

7. Checking ATF level and topping up 101

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
Volkswagen AG
The ⇒ ATF temperature should not be more than approx.age30°
n AG.C does
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at the start of the test. by
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• Gearbox not in emergency running mode; ho ATF
ri temperature eo
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not above approx. 30° C ss
a ra
c

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• Vehicle must be standing level

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• Selector lever in “P”.

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ility
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– Connect “tester” and continue to switch until it is ready for op‐

wit
eration ⇒ page 43 .
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hole

– Press guided functions .

spec
es, in part or in w

t to the co
– Then select vehicle, the gearbox and Check ATF level .
– Press → .

rrectness of i
– Start engine.
l purpos

– Raise vehicle.

nform
ercia

– Remove noise insulation tray -arrows-.

m

at
– Place drip tray under gearbox.
om

ion
c

in t
– Press → .
or

his
ate

do
riv

If a test temperature between 35° C and 45° C is displayed:

p

cum
for

en
ng

t.
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Prote AG.

– Remove ATF inspection plug from pan -arrow-.

The ATF present in the overflow pipe runs out.

If ATF drips out of drilling:
ATF does not need topping up.
– Fit new seal to plug and tighten to 15 Nm. This completes the
ATF check.
If no ATF drips out of inspection hole:
– Top up ATF ⇒ page 103 .

102 Rep. Gr.37 - Controls, housing

 AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
autho eo
ra Passat 1997 ➤
ss 4-speed automatic gearbox 01N - Edition 10.2005
c

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e
nl

pt
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7.2 Topping up ⇒ ATF
itte

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erm

ab
ility
– With engine “running”, screw in adapter for filling oil -VAS
ot p

wit
6262/2- hand tight.
, is n

h re
hole

– Add 1 litre of ATF.

spec
es, in part or in w

– Pull off adapter for oil filling -VAS 6262- at quick-release con‐

t to the co
nection and check:
If ATF now flows out of hole in adapter:

rrectness of i
ATF does not need topping up.
l purpos

– Drain ATF until it drips.

nf
ercia

– Fit new seal to plug and tighten to 15 Nm. This completes the

or
ATF check.

m
m

atio
m

If no ATF drips out:

o

n in
or c

thi
e

– Add another litre ⇒ page 103 .

t

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en
WARNING
ng

t.
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Cop py
t. rig
An ATF level which is too low or too high will impair the function
gh ht
yri by
of the gearbox. But if the gearbox was 2 litres low, it must be
cop Vo
by lksw
cted
carefully inspected. There is probably a “major” leak.
agen
Prote AG.

7.3 Draining and filling ⇒ ATF

– Switch off engine.

– Remove ATF inspection plug from pan -arrow-.

7. Checking ATF level and topping up 103

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove overflow pipe through inspection hole.

– Drain ATF.
– Install overflow pipe.

If ATF must be added, use (ATF as a replacement part).

– Fill with approx. 3 litres of ATF through filler pipe.
– Screw in plug hand-tight.
– Then start engine and shift through all selector lever positions
with vehicle stationary.
– Finally, check ATF level and top up ⇒ page 100 .

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ility
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ole,

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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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c

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or

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te

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104
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Prote AG.
Rep. Gr.37 - Controls, housing
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8 Gearbox with selector elements

Position of selector elements
Before carrying out repairs to gearbox first perform “guided fault
finding” with -VAS 5051- .

1 - 2nd and 4th gear brake -B2-

2 - Reverse gear clutch -K2-
3 - 1st through 3rd gear clutch
-K1-
4 - 3rd and 4th gear clutch -K3-
5 - Reverse gear brake -B1-
6 - Freewheel
7 - Lock-up clutch integrated in
⇒ torque converter -LC-

AG. Volkswagen AG d
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erm

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es, in part or in w

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Position of selector elements

r
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The following table shows which selector elements are operated

t.
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op
in the individual gears to help you deal with complaints regarding C py
t. rig
poor acceleration and speed performance or generally with drive
gh ht
pyri by
train faults. The table makes it possible to determine which se‐
o Vo
by c lksw
cted
lector elements are not operating properly.
agen
Prote AG.

All gears will be shifted hydraulically.

All forward gears are driven mechanically at a predetermined load
and speed via the torque converter lock-up clutch.
Gear B1 B2 K1 K2 K3 F LC
R X X
1H X X
1M X X X

8. Gearbox with selector elements 105

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Gear B1 B2 K1 K2 K3 F LC
2H X X
2M X X agen
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X X X tee
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4H X ss X

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4M X X X

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X = ⇒ clutches, ⇒ brakes or freewheel engaged

ility
ot p

H = hydraulic

wit
is n

h re
M = mechanical
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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t.
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Cop py
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by
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Prote AG.

106 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9 Dismantling and assembling gearbox

– Observe general repair instructions ⇒ page 11 .
Removing and installing ⇒ ATF lines ⇒ page 107
Cleaning ⇒ ATF lines and ⇒ ATF cooler ⇒ page 111
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Overview - dismantling and assembling ⇒ planetary yV
ogearbox
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⇒ page 111 ed b ran
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Dismantling ⇒ page 118 aut or
ac
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Assembling ⇒ page 125

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Installing exchange component ⇒ page 134 itte

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ab
ility
Overview - all ⇒ planetary gearbox adjustments ⇒ page 144
ot p

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is n

Dismantling and assembling ⇒ ATF pump ⇒ page 165

h re
ole,

spec
Removing and installing ⇒ valve body ⇒ page 181
urposes, in part or in wh

t to the co
Dismantling and assembling ⇒ parking lock ⇒ page 192

9.1 Removing and installing ⇒ ATF lines

rrectne
– Observe general repair instructions ⇒ page 11 .

ss
– Thoroughly clean area around connection between ⇒ ATF line

o
cial p

f
and gearbox.

inform
mer

– Unscrew bolt -2-.

atio
om

– Pull ⇒ ATF lines off gearbox.

n
c

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or

n thi
e

– Always renew O-rings -1-.

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– Moisten O-rings with ⇒ ATF.

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fo

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– Before installing gearbox, thoroughly clean ⇒ ATF lines and ⇒
Co
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– Ensure that O-rings are seated correctly so that they do not by c lksw
cted agen
slip from their seats when ⇒ ATF lines are inserted. Prote AG.

– Insert ⇒ ATF lines completely to stop in gearbox by hand.

– Do not tighten bolt -2- until all ⇒ ATF lines have been com‐
pletely inserted ⇒ Item 27 (page 110) .
– Then check ⇒ ATF level and top up ⇒ page 100 .
– When checking ⇒ ATF level, check ⇒ ATF line connections
-A- and -B- for leaks.
Removing and installing other connections of ⇒ ATF lines
Injection engines without air conditioning (1.6 l/75 kW through
04.01 with or without air conditioning) ⇒ page 107 .
Injection engines with air conditioning (1.8 l/92 kW with or without
air conditioning, 1.6 l/75 kW from 05.01 with or without air condi‐
tioning), diesel engines with or without air conditioning
⇒ page 109 .

9.1.1 Injection engines without air conditioning (1.6 l/75 kW through 04.01 with or
without air conditioning)
Before installing ⇒ ATF lines, ensure that O-rings are properly
seated and do not slip from their seats when lines are inserted.

9. Dismantling and assembling gearbox 107

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - ⇒ ATF lines
❑ From upper cooler con‐
nection to top of gear‐
box.
❑ Installation position: se‐
cure lower retainer over
retaining tab of ⇒ ATF
line
⇒ Item 6 (page 108)
with hexagon bolt
⇒ Item 3 (page 108)
-arrow-.
2 - O-ring
❑ Insert with ⇒ ATF.
❑ Always renew
3 - Hexagon bolt, 5 Nm
❑ Before tightening bolt,
push in line to stop by
hand. agen
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4 - Union nut, 30 Nm ed by gu
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❑ Mark lines before loos‐ ut
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5 - Shielded hose

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6 - ⇒ ATF lines
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ility
❑ From bottom of gearbox
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to lower cooler connec‐
, is n

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tion.
hole

spec
❑ At the same time, se‐
es, in part or in w

cure lower retainer for ⇒

t to the co
ATF line
⇒ Item 1 (page 108)
-arrow-.

rrectness of i
❑ Installation position: se‐
l purpos

cure lower retainer of ⇒

ATF line ⇒ Item 1 (page 108) over retaining tab with hexagon bolt ⇒ Item 3 (page 108) -arrow-.

nform
ercia

7 - Hexagon bolt, 25 Nm
m

❑ For cast iron engine. at

om

ion
c

8 - Hexagon nut, 25 Nm
in t
or

his
te

❑ For aluminium engine.

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or

9 - Centre hex stud, 45 Nm

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ng

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❑ For aluminium engine.
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10 - ⇒ ATF lines
ht
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❑ Double line. Prote
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agen

❑ Mark lines ⇒ Item 1 (page 108) and ⇒ Item 6 (page 108) before removal.
❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
11 - Hexagon bolt, 10 Nm
❑ Self-tapping bolt.
12 - Clip
❑ Push onto gearbox.
❑ Lug engages in notch of line retainer.
13 - Hexagon bolt, 20 Nm
❑ Before tightening bolt, push in line to stop by hand.

108 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9.1.2 Injection engines with air conditioning (1.8 l/92 kW with or without air con‐
ditioning, 1.6 l/75 kW from 05.01 with or without air conditioning), diesel
engines with or without air conditioning
Before installing ⇒ ATF lines, ensure that O-rings are properly
seated and do not slip from their seats when lines are inserted.

1 - ⇒ ATF lines
❑ From upper cooler con‐
nection to top of gear‐
box.
❑ Installation position: se‐
cure lower retainer over
retaining tab of ⇒ ATF
line
⇒ Item 2 (page 109)
with hexagon bolt
⇒ Item 4 (page 109)
-arrow-.
2 - ⇒ ATF lines
❑ From bottom of gearbox
to lower cooler connec‐
tion.
❑ At the same time, se‐
cure lower retainer for ⇒
ATF line
⇒ Item 1 (page 109)
-arrow-.
❑ Installation position: se‐
cure lower retaineragen of ⇒
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⇒ Item
ised b 1 (page 109) ara
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over
ut
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retaining tab with eo
ss a hexagon bolt ra
c
⇒ Item 4 (page 109)
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nl

-arrow-.
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3 - O-ring
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ility
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❑ Insert with ⇒ ATF.

wit
, is n

❑ Always renew
h re
hole

spec

4 - Hexagon bolt, 5 Nm
es, in part or in w

t to the co

❑ Before tightening bolt,

push in line to stop by
hand.
rrectness of i

5 - Bracket
l purpos

6 - Hexagon bolt, 5 Nm
7 - Line retainer
nf
ercia

or

❑ Engage in retainer ⇒ Item 5 (page 109) and turn 90°.

m
m

atio
m

8 - Union nut, 30 Nm
o

n in
or c

thi

❑ Mark lines before loosening.

te

sd
iva

o
r

9 - ⇒ ATF lines
rp

cu
o

m
f

en
ng

❑ From upper cooler connection to top of gearbox.

t.
yi Co
op
❑ Mark lines before removal.
C py
t. rig
gh ht
yri
❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
p by
o Vo
by c lksw
cted agen
10 - ⇒ ATF lines
Prote AG.

❑ From bottom of gearbox to lower cooler connection.

9. Dismantling and assembling gearbox 109

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
❑ Mark lines before removal.
❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
11 - Shielded hose
12 - Shielded hose
13 - Bracket
Vehicles through model year 1999
❑ On engine/gearbox support.
14 - Hexagon bolt
Vehicles through model year 1999
❑ Need not be unscrewed to remove and install ⇒ ATF lines.
15 - Hexagon nut, 5 Nm
Vehicles through model year 1999

16 - Clamp
Vehicles through model year 1999

17 - Bracket
Vehicles from model year 2000.
❑ On engine sump.
18 - Hexagon bolt, 10 Nm
Vehicles from model year 2000.

19 - Hexagon bolt, 10 Nm
. Volkswagen AG
gen AG does
Vehicles from model year 2000.Volkswa not
by gu
ara
ed
20 - Clamp horis nte
eo
ut ra
Vehicles from model sa
syear 2000. c
ce
le
un

pt

21 - Hexagon bolt, 10 Nm
an
d
itte

y li
rm

ab

22 - Union nut, 30 Nm
pe

ility
ot

❑ Mark lines before loosening.

wit
, is n

h re

23 - Clamp
hole

spec

❑ Diesel engines only.

es, in part or in w

t to the co

24 - Hexagon bolt, 5 Nm
❑ Diesel engines only.
rrectness of i

25 - Bracket
l purpos

❑ Push onto gearbox to stop.

26 - ⇒ ATF lines
nform
ercia

❑ Mark lines ⇒ Item 9 (page 109) and ⇒ Item 10 (page 109) before removal.
m

a
com

❑ Double line.
ion in
r

❑ Push on to gearbox by hand completely to stop.

te o

thi
s
iva

❑ Allocation ⇒ Electronic parts catalogue “ETKA” .

do
r
rp

cum
fo

27 - Hexagon bolt, 20 Nm
en
ng

t.
yi Co
❑ Before tightening bolt, push in line to stop by hand. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

110 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9.2 Cleaning ⇒ ATF lines and ⇒ ATF cooler

Before installing gearbox, always blow compressed air (not more
than 10 bar) through ATF cooler and ⇒ ATF lines.

WARNING

Wear eye protection.

– Separate retainer for rigid ⇒ ATF lines on gearbox and engine

⇒ page 107 .
– Unscrew bolt -2-.
– Pull ⇒ ATF lines off gearbox.
– Connect a hose to ⇒ ATF line -A- and secure with a hose clip.
Hang other end of hose in a suitable container.
– Using a compressed air pistol, repeatedly blow air through ⇒
ATF line -B-.
– Change hose from ⇒ ATF line -A- over to ⇒ ATF line -B- and
repeat procedure.
– Do not tighten bolt -2- until all ⇒ ATF lines have been com‐
pletely inserted ⇒ Item 27 (page 110)
wage
n AG. .Volkswagen AG do
e
olks s no
t gu
– Secure ⇒ ATF lines again
ed
by ⇒ page 107 .
V
ara
is nte
or
– Then check ⇒ ATF
au level and top up ⇒ page 100 .
th eo
ra
ss c
– When checking ⇒ ATF level, check ⇒ ATF line connections
ce
e
nl

pt

-A- and -B- for leaks.

du

an
itte

y li
erm

ab

9.3 Overview - dismantling and assembling ⇒ planetary gearbox

ility
ot p

wit
, is n

h re

Dismantling ⇒ planetary gearbox ⇒ page 118 ,

hole

spec

Assembling ⇒ page 125 .

es, in part or in w

t to the co

Installing exchange component ⇒ page 134 .

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

9. Dismantling and assembling gearbox 111

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

I - Removing and installing ⇒

ATF pump to support tube
⇒ page 112
II - Removing and installing re‐
verse clutch -K2- to large sun
gear ⇒ page 114
The small sun gear -arrow 1-
can be removed from the plan‐
et carrier only in gearboxes
“DFG”, “DMU” and “EPT”.
III - Removing and installing
freewheel and reverse gear
brake -B1- ⇒ page 115
To remove and install free‐
wheel, pan, ATF strainer and ⇒
valve body with plugs must be
removed ⇒ page 181 .

IV - Removing and installing

planet carrier ⇒ page 116
It is not necessary to remove
input gear -arrow 2-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

9.4 I - Removing and installing ⇒ ATF pump to support tube

rrectness of i

Overview ⇒ page 111

l purpos

Dismantling ⇒ planetary gearbox ⇒ page 118 ,

nf
ercia

Assembling ⇒ page 125 .

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

112 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
AG. Volkswagen AG d
agen oes
Installing exchange component ⇒ page 134 . olksw not
y V gu
d b ara
rise nte
tho eo
u
1 - Bolt ss a ra
c
❑ Qty. 7

ce
le
un

pt
an
d
❑ Tighten to 8 Nm and turn

itte

y li
90° further.

erm

ab
ility
ot p
❑ The additional 90° turn

wit
is n
may be done in several

h re
ole,
stages.

spec
urposes, in part or in wh
2 - ⇒ ATF pump with -B2- pis‐

t to the co
ton
❑ Dismantling and assem‐
bling ⇒ page 165

rrectne
❑ To install strainer
⇒ Item 15 (page 114) ,

ss
a corresponding notch

o
cial p

f
in flange of ⇒ ATF pump

inform
is required.
mer

atio
m

3 - O-ring
o

n
c

i
or

n
❑ Always renew

thi
te

sd
a

❑ Place on ⇒ ATF pump.

iv

o
pr

cum
r
fo

4 - Seal

en
ng

t.
yi Co
❑ Always renew Cop py
t. rig
gh ht
yri
5 - Retaining ring p by
co Vo
by lksw
cted
❑ Not installed in gearbox‐
agen
Prote AG.
es DFG, DFH and DFK.
6 - Shim
❑ Not installed in gearbox‐
es DFG, DFH and DFK.
❑ Determining thickness
⇒ Adjusting reverse
gear brake -B1-
⇒ page 150 .
7 - Spring cap, Qty. 6
❑ Install 3 spring caps after installing first outer plate.
❑ Install 3 spring caps before installing last outer plate.
8 - Spring
❑ Qty. 3
9 - Corrugated washer
❑ Installed only in gearboxes DFG, DFH and DFK.
10 - Outer plate -B2-
❑ Always install a 3 mm thick outer plate.
❑ Only in gearboxes DFG, DFH and DFK with built-in corrugated washer ⇒ Item 9 (page 113) is it necessary
to ascertain the thickness of the outer plate in order to adjust -B2- ⇒ Adjusting 2nd and 4th gear brake -
B2- ⇒ page 157 .
11 - Inner plate -B2-
❑ Quantity ⇒ page 7 .
❑ Lay new inner plates in ⇒ ATF for 15 minutes before installing.
12 - Outer plate -B2-
❑ Always install 2 mm thick outer plates.
❑ Quantity ⇒ page 7 .

9. Dismantling and assembling gearbox 113

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

13 - Outer plate -B2-

❑ Fit 3 mm thick outer plate to support tube.
14 - Support tube -B2-
❑ For -B2- plate set.
❑ Insert so that notch locates on wedge of freewheel.
❑ Parts are allocated according to gearbox code letters.
15 - Strainer
❑ Installed only from gearbox date 06 07 8.
❑ Location: in return line from ⇒ ATF cooler.
❑ To install strainer, a corresponding notch in gearbox housing is required.
16 - Gearbox housing with ⇒ clutches installed

9.5 II - Removing and installing reverse clutch -K2- to large sun gear
Overview ⇒ page 111
AG. Volkswagen AG d
agen oes
Dismantling ⇒ planetary gearbox ⇒ page 118 , olksw not
V gu
d by ara
e
Assembling ⇒ page 125 . horis nte
eo
aut ra
Installing exchange component ⇒ page 134 s.
s c

ce
le
un

pt
an
d
itte

y li
1 - Reverse gear clutch -K2-
rm

ab
pe

❑ Dismantling and assem‐

ility
ot

bling ⇒ page 172

wit
, is n

h re
hole

2 - Shim

spec
es, in part or in w

❑ Determining thickness

t to the co
⇒ Adjusting clutch play
between -K1- and -K2-
⇒ page 153 .

rrectness of i
❑ Up to 3 shims can be in‐
stalled.
l purpos

3 - 1st through 3rd gear clutch

-K1- nform
ercia

❑ ⇒ Clutches -K1- and -

m

a
com

K3- may be pressed to‐

ion in

gether in some gearbox‐

r
te o

thi

es.
s
iva

do

❑ Pressing -K1- off -K3-

r
rp

cum
fo

⇒ page 124 .
en
ng

t.
yi Co
❑ Dismantling and assem‐ Cop py
bling ⇒ page 169
t. rig
gh ht
pyri by
❑ Pressing -K1- onto -K3-
o Vo
by c lksw
cted
⇒ page 124 .
agen
Prote AG.

4 - O-ring
❑ Always renew
❑ To renew O-ring, press -
K1- off -K3-
⇒ page 124 .
5 - 3rd and 4th gear clutch -K3-
with turbine shaft
❑ Parts are allocated ac‐
cording to gearbox code
letters.
❑ ⇒ Clutches -K1- and -

114 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
AG. Volkswagen AG d
agen oes
lksw not
K3- may be pressed byV
o to‐ gu
ara
gether in some
rised
gearboxes. nte
ho eo
❑ Pressing
s aut-K1- off -K3- ⇒ page 124 . ra
c
s
❑ Dismantling and assembling ⇒ page 175

ce
le
un

pt
❑ Pressing -K1- onto -K3- ⇒ page 124 .

an
d
itte

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erm

❑ There are two different versions ⇒ page 37 .

ab
ility
ot p

6 - 1st to 3rd gear clutch -K1- with 3rd and 4th gear clutch -K3-

wit
is n

h re
❑ ⇒ Clutches -K1- and -K3- are pressed together.
ole,

spec
urposes, in part or in wh

❑ Pressing -K1- off -K3- ⇒ page 124 .

t to the co
❑ Pressing -K1- onto -K3- ⇒ page 124 .
7 - Needle thrust bearing with washer

rrectne
❑ Needle thrust bearing faces small input shaft
8 - Small input shaft

ss o
cial p

9 - Needle bearing

f inform
mer

10 - Needle thrust bearing

atio
m

11 - Large input shaft

o

n
c

i
or

n thi
e

12 - Needle thrust bearing

t

sd
iva

o
pr

c
13 - Needle thrust bearing washer

um
r
fo

en
ng

❑ With shoulder.
t.
yi Co
Cop py
.
14 - Large sun gear
ht rig
rig ht
py by
co Vo
15 - Needle thrust bearing
by lksw
cted agen
Prote AG.
16 - Needle thrust bearing washer
17 - Small sun gear
❑ Can be removed from planet carrier only in gearboxes “DFG”, “DMU” and “EPT”.
18 - Gearbox housing with freewheel and retaining rings installed
19 - Planet carrier shim
❑ Determining thickness, ⇒ Adjusting planet carrier ⇒ page 146 .
20 - Washer
21 - Bolt, 30 Nm
❑ For small input shaft.
22 - Cover

9.6 III - Removing and installing freewheel and reverse gear brake -B1-
Overview ⇒ page 111
Dismantling ⇒ planetary gearbox ⇒ page 118 ,
Assembling ⇒ page 125 .

9. Dismantling and assembling gearbox 115

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Installing exchange component ⇒ page 134 .

1 - Retaining ring
❑ For support tube -B2-.
❑ Insert baffle plate before
inserting retaining ring.
❑ Installation position:
open ends of retaining
ring face freewheel re‐
taining wedge.
2 - Baffle plate
❑ Insert before fitting re‐
taining ring
⇒ Item 1 (page 116) .
3 - Retaining ring
❑ For freewheel.
❑ Installation position:
open ends of retaining
ring face freewheel re‐ . Volkswage
taining wedge. kswagen AG n AG d
oes
n ol ot g
yV ua
4 - Freewheel with ed -B1- piston
b ran
oris tee
❑ Before au removing free‐
th or
ac
wheel,
ss remove ⇒ valve
body and plug
ce
le
un

pt

⇒ page 181 .
an
d
itte

y li

❑ Dismantling and assem‐

erm

ab
ility

bling ⇒ page 167

ot p

wit
is n

5 - Dished spring
h re
ole,

spec

❑ Smaller diameter faces

urposes, in part or in wh

freewheel.
t to the co

6 - Pressure plate -B1-

❑ Install with flat side fac‐
rrectne

ing plates.
❑ Parts are allocated ac‐
ss

cording to gearbox code

o
cial p

letters.
inform
mer

7 - Inner plate -B1-

atio
m

❑ Quantity of inner plates -B1- ⇒ page 7 .

o

n
c

i
or

❑ Lay in ⇒ ATF for 15 minutes before installing

thi
te

sd
va

8 - Outer plate -B1-

i

o
pr

cum
r
fo

❑ Quantity of outer plates -B1- ⇒ page 7 .

en
ng

t.
yi Co
op
9 - Shim
C py
t. rig
gh ht
yri
❑ Determining thickness ⇒ Adjusting reverse gear brake -B1- ⇒ page 150 .
p by
o Vo
by c lksw
cted
❑ 1 or 2 shims may be installed.
agen
Prote AG.

10 - Gearbox housing with planet carrier installed

9.7 IV - Planet carrier and gearbox housing with input gear and cover
Overview ⇒ page 111
Dismantling ⇒ planetary gearbox ⇒ page 118 ,
Assembling ⇒ page 125 .

116 Rep. Gr.37 - Controls, housing

 AG. Volkswagen AG d
agen oes
ksw
gPassat 1997 ➤
ol not
V
d by ua
is 4-speed automatic gearbox 01N - Edition 10.2005
e ran
r te
tho eo
au ra
c
Installing exchange component ⇒ page 134
s .
s

ce
le
un

pt
an
d
itte

y li
1 - Planet carrier

rm

ab
pe

ility
❑ Adjusting ⇒ page 146

ot

wit
, is n
2 - O-ring

h re
hole

spec
❑ Always renew

es, in part or in w
❑ Insert in planet carrier.

t to the co
3 - Needle thrust bearing
washer

rrectness of i
4 - Needle thrust bearing
l purpos

5 - Needle thrust bearing

washer

nform
ercia

❑ Install smooth side in in‐

m

a
put gear.
com

tion in
6 - Gearbox housing with input
r
te o

thi
gear installed

s
iva

do
r
rp

c
7 - Input gear

um
fo

en
ng

t.
❑ Do not remove to dis‐
yi Co
op
mantle ⇒ planetary
C py
t. rig
gh
gearbox.
ht
pyri by
Vo
o
by c lksw
❑ Removing and installing Prote
cted AG.
agen
input gear or needle
thrust bearing for planet
carrier ⇒ page 208

9. Dismantling and assembling gearbox 117

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9.8 Dismantling ⇒ planetary gearbox

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Thrust plate -VW 402-
♦ Press tool -VW 412-
♦ Tube -VW 415 A-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

118 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Tube -VW 418 A-

♦ Tube -3110-
♦ Gearbox mounting support
-3336-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Observe general repair instructions ⇒ page 11 .

nform
ercia

• Gearbox is attached to gearbox lifting tackle -3336- .

m

a
com

tio

– Place drip tray under gearbox.

n in
r
te o

thi

– Remove plug -1- and ⇒ ATF overflow pipe -2-.

s
iva

do
r
rp

– Drain ⇒ ATF.
um
fo

en
ng

t.
yi
3 - Plug
Co
Cop py
t. rig
gh
4 - Cap
ht
pyri by
Vo
co lksw
by
– Take out ⇒ torque converter.
cted agen
Prote AG.

9. Dismantling and assembling gearbox 119

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Secure gearbox to assembly stand with bolts -1- and -2-.

– Remove cover.
– Remove oil pan ⇒ page 178 .
– If metal particles are present in the remaining ⇒ ATF, renew
⇒ torque converter and gearbox.
– Remove ATF strainer ⇒ page 180 .

– Remove ⇒ valve body with conductor strip ⇒ page 181 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Pull out plug for -B1-.

orm
m

– Remove gearbox speed sender -G38- ⇒ Item 7 (page 46) .

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

120 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove ⇒ ATF pump bolts -arrows-.

– Mark installation position of ⇒ ATF pump in gearbox housing.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
– Screw bolts -A- (M 8) into tapped holes of ⇒ ATF pump.
urposes, in part or in wh

t to the co
– Press ⇒ ATF pump off gearbox housing by evenly turning bolts
-A- and remove.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
r

– Remove strainer if present.

p

cum
r
fo

en
ng

The strainer is located in return line from ⇒ ATF cooler.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull out all ⇒ clutches with support tube, -B2- plates, springs
and spring caps together on turbine shaft upwards -arrow-.
⇒ Clutches -K1- and -K3- may be pressed together in some gear‐
boxes.
Clutch -K1- must be pressed off -K3- only if one of the ⇒ clutches
is to be dismantled or renewed.
Pressing -K1- off -K3- ⇒ page 124 .
– Engage ⇒ parking lock.

9. Dismantling and assembling gearbox 121

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert screwdriver through holes of “large sun gear” to loosen

and tighten “bolt for small input shaft”.
– If ⇒ parking lock cannot be engaged, also block large input
shaft with a second screwdriver.

– Loosen “small input shaft” bolt -1-.

– Remove bolt, washer -2- and shim -3- for “small input shaft”.
Needle thrust bearing for planet carrier remains in gearbox in‐
put gear.
– Remove screwdriver.
– Pull out small input shaft.

– Pull out large input shaft -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt

– Pull out large sun gear -arrow-.

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen

122
Prote AG.
Rep. Gr.37 - Controls, housing
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove retaining ring -a- for support tube of -B2-.

– Pull off baffle plate -2-.

1 - ⇒ ATF breather hole

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
– Remove retaining ring -b- for freewheel.

an
d
itte

y li
rm

ab
– Take freewheel out of gearbox housing by pulling on freewheel
pe

ility
retaining wedge -arrow- with pliers.
ot

wit
, is n

h re
Only gearboxes DFG, DMU, EPT
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Remove small sun gear with washer and needle thrust bearing
from planet carrier.
m

a
com

tio

1- Needle thrust bearing

n in
r
te o

thi

2- Needle thrust bearing washer

s
iva

do
r
rp

cum

3- Small sun gear

fo

en
ng

t.
yi
4- Planet carrier
Co
Cop py
t. rig
gh ht
Continued for all gearboxes yri
p by
o Vo
by c lksw
cted agen
Prote AG.

9. Dismantling and assembling gearbox 123

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove only axial bearing and washer from small sun gear of
planet carrier.
1- Needle thrust bearing
2- Needle thrust bearing washer
3- Planet carrier (with small sun gear installed)

– Pull out planet carrier together with freewheel and dished

spring.
– Remove pressure plate, plates and shim(s) of reverse gear
brake -B1-. n AG. Volkswagen AG do
lkswage es n
o ot g
– Remove axial bearing and washer. d byV ua
ran
ir se tee
It is not necessary to remove input gear in order to dismantle
utho ⇒ or
planetary gearbox. Removing and installing input sgear
s a ac
⇒ page 208 .

ce
e
nl

pt
du

an
Assembling ⇒ planetary gearbox ⇒ page 125 .
itte

y li
erm

ab
– Clean⇒ ATF lines and ⇒ ATF cooler

ility
ot p

⇒ page 111 .

wit
, is n

h re
hole

spec
9.8.1 Pressing clutch -K1- off -K3-
es, in part or in w

t to the co
⇒ Clutches -K1- and -K3- may be pressed together in some gear‐
boxes.

rrectness of i
Clutch -K1- must be pressed off -K3- only if one of the ⇒ clutches
is to be dismantled or renewed.
l purpos

– Ensure that pressing surfaces of tools are flat and undam‐

aged.

nform
ercia

The pin of tube -3110- faces pressure plate -VW 402- .

m

at
om

io
– Hold turbine shaft when pressing off.
n
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9.8.2 Pressing -K1- onto -K3-

– Moisten O-rings with ⇒ ATF.

124 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert new O-ring in groove in turbine shaft -arrow-.

– Clip needle thrust bearing -1- with washer to 3rd and 4th gear
clutch -K3- -2-.
– Ensure that pressing surfaces of tools are flat and undam‐ wagen AG. Volkswagen AG doe
aged. yV
olks s no
t gu
b ara
ed nte
oris e
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
– Prepare -K1- and -K3- for pressing as shown here.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Before pressing on, centre tube -VW 418 A- on surface for

needle thrust bearing (this illustration shows -K3- from below).
– Carefully press clutch -K1- on until stop is felt.
– Do not exert further pressure on ⇒ clutches!

9.9 Assembling ⇒ planetary gearbox

9. Dismantling and assembling gearbox 125

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Thrust plate -VW 402-
♦ Press tool -VW 412-
♦ Tube -VW 415 A-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

126 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Tube -VW 418 A-

♦ Drift sleeve -40 - 20-
♦ Tube -3110-
♦ Assembly ring -3267-
♦ Gearbox mounting support
-3336-
♦ Torque wrench -
V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

An exchange component is available for the repair of the auto‐

matic gearbox ⇒ page 17 . It is allocated according to gearbox
ss

code ⇒ page 7 .
o
cial p

f in

Installing exchange component ⇒ page 134 .

form
mer

atio

– Place new O-ring -arrow- into planet carrier.

om

n
c

If planet carrier is renewed, adjust planet carrier. ⇒ page 146 .

or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 127

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert needle thrust bearing with washers and planet carrier

into input gear.
1- Input gear, installed in gearbox housing ⇒ page 111
2- Needle thrust bearing washer, insert smooth side into input
gear.
AG. Volkswagen AG d
agen
3- Needle thrust bearing olksw
oes
not
byV gu
ara
d
4- Needle thrust bearing washer orise nte
eo
h
ut ra
5- Install planet carrier with O-ring fitted.
ss a c

ce
e
nl
Only gearboxes DFG, DMU, EPT

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Insert small sun gear with washer and needle thrust bearing

rrectness of i
into planet carrier.
l purpos

1- Needle thrust bearing

2- Needle thrust bearing washer

nf
ercia

orm
3- Small sun gear
m

atio
om

n in
4- Planet carrier
or c

thi
te

– Centre washer and needle thrust bearing in “small sun gear”.

sd
iva

o
r
rp

cu
Continued for all gearboxes
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
– Set washer -2- and needle thrust bearing -1- on “small sun co Vo
by lksw
gear” in planet carrier -3-. cted agen
Prote AG.

– Centre washer and needle thrust bearing in “small sun gear”.

– Insert shim and inner and outer plates of -B1- in the sequence
given in ⇒ page 115 .
Determine shim ⇒ page 150 .
– Insert pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates.
Replacement parts are allocated according to gearbox codes.

– Insert dished spring with smaller diameter facing freewheel.

If any of the following components are renewed, -B1- must be
adjusted:
♦ Gearbox housing
♦ Freewheel
♦ Piston for reverse gear brake -B1-
♦ or plates
Determine shim ⇒ page 150 .

128 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Preload freewheel rollers with assembly ring -3267- and insert

freewheel.

– Installation position of freewheel: retaining wedge -arrow-

must be inserted in machined groove in gearbox housing.
– Install retaining ring -b- for freewheel.
– Position gaps of retaining ring on freewheel retaining wedge
-arrow-.
– Insert baffle plate -2- in groove in gearbox housing in which ⇒
ATF breather hole -1- is located.

– Install retaining ring -a- for support tube of -B2-.

– Position gaps of retaining ring on freewheel retaining wedge
-arrow-.
– Install gearbox speed sender -G38- ⇒ Item 7 (page 46) .
– Check dimensions of -B1- ⇒ page 152 .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

– Insert components into gearbox housing starting with large y li

erm

ab
sun wheel down continuing to small input shaft. ility
ot p

wit
, is n

1- Large sun gear

h re
hole

spec

2- Washer for needle thrust bearing (shoulder faces large sun

es, in part or in w

gear)
t to the co

3- Needle thrust bearing

4- Large input shaft
rrectness of i

5- Needle thrust bearing

l purpos

6- Needle bearing
nf
ercia

7- Small input shaft

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 129

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install bolt for small input shaft -1- with washer -2- and shim
-3-.
Torque setting ⇒ Item 21 (page 115)
– Set shim -3- onto small input shaft shoulder -arrow-.
Determine shim thickness -3- ⇒ Adjusting planet carrier
⇒ page 146 .
– Check dimensions of planet carrier ⇒ page 149 .

– Insert new O-ring in groove in turbine shaft -arrow-.

– Moisten O-rings with ⇒ ATF.
olkswagen AG
wag en AG. V
⇒ Clutches -K1- and -K3- must Vbeolkspressed together before sin‐
doe
not
stallation in some gearboxes.
ed by gu
ara
is nte
or
⇒ Clutches that are notautpressed
h together: eo
ra
ss c
– Check whether clutch -K1- can be fully pushed onto turbine

ce
le
un

pt
shaft teeth of -K3-.

an
d
itte

y li
– Push -K1- onto -K3- by hand.
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
– If the teeth -arrow 1- are visible in the hub of -K1-, then the two
urposes, in part or in wh

⇒ clutches must be pressed together ⇒ page 124 .

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

If the resistance of the O-ring has been overcome when parts are
um
r
fo

pressed together by hand, the teeth -arrow 1- of -K1- can no lon‐

en
ng

t.
yi
ger be seen.
Co
Cop py
t. rig
gh
Then the ⇒ clutches do not need to be pressed together.
ht
pyri by
Vo
co lksw
by
cted
– The assembly of the gearbox can be continued.
agen
Prote AG.

130 Rep. Gr.37 - Controls, housing

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ho
ir se tee Passat 1997 ➤
t or
au 4-speed automatic gearbox ac 01N - Edition 10.2005
ss

ce
le
un
– Place needle thrust bearing with washer on 3rd and 4th gear

pt
an
d
itte
clutch -K3-.

y li
rm

ab
pe
1 - Needle thrust bearing with washer

ility
ot

wit
, is n
Moisten needle thrust bearing washer with ⇒ ATF so that bearing

h re
hole
adheres to -K3- during installation. Place washer of bearing onto

spec
-K3-.
es, in part or in w

t to the co
2 - 3rd and 4th gear clutch -K3-

rrectness of i
l purpos

– Ensure that piston rings seat correctly on -K3-.

nform
ercia

– Ensure that ends of piston rings are hooked together.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert 3rd and 4th gear clutch -K3-.

Turn 3rd and 4th gear clutch -K3- when inserting until all plates
mesh.
– Insert O-ring -1- in groove -arrow-.
– Moisten O-rings with ⇒ ATF.

– Insert 1st to 3rd gear clutch -K1-.

If -K1- and -K3- are pressed together, then the two ⇒ clutches can
only be installed together.

9. Dismantling and assembling gearbox 131

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert shims -arrow- into -K1-.

– If -K1-, -K2- or ⇒ ATF pump is renewed, or an exchange com‐
ponent is installed, shim must be measured again ⇒ Adjusting
clutch play between -K1- and -K2- ⇒ page 153 .
AG. Volkswagen AG d
agen
Up to 3 shims may be installed. Volksw
oes
not
gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

– Insert reverse gear clutch -K2-.

h re
ole,

spec
When inserting, turn clutch -K2- until all plates mesh.
urposes, in part or in wh

t to the co
– Insert support tube for -B2- plate set so that notch in support
tube engages in retaining wedge of freewheel.
If the following components are renewed, the 2nd and 4th gear

rrectne
brake -B2- must be adjusted ⇒ page 157 :

s
♦ Gearbox housing

s o
cial p

f i
♦ Support tube

nform
mer

♦ ⇒ ATF pump

atio
om

n
♦ Corrugated washer or retaining ring
c

i
or

n thi
te

sd
♦ Retaining ring
iva

o
pr

cum
r

♦ or plates
fo

en
ng

t.
yi Co
Replacement parts for these components are allocated according Cop py
t. rig
to gearbox codes. opyri
gh by
Vo
ht
by c lksw
cted agen
– Install -B2- plates as follows: Prote AG.

– First insert a 3 mm thick outer plate.

– Place three spring caps in outer plate.
– Insert compression springs -arrows-.
– Insert all but last outer plate.
– Place three spring caps onto compression springs.
The thickness of the last outer plate determines the play of ⇒
brake -B2- only in gearboxes with built-in corrugated washer.
For calculating the thickness of this plate, see ⇒ page 161 .
– Insert last - measured - outer plate.
– Insert corrugated washer.

132 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

In all other gearboxes (with retaining ring -b-), the last outer plate
is also always 3 mm thick. The play of ⇒ brake -B2- is determined
by shim -a- that is placed on retaining ring -b-. There is no corru‐
gated washer.
– Insert last outer plate, 3 mm thick.
Determine shim ⇒ page 157 .
– Insert shim.
– Set retaining ring -b- onto shim. Smooth side faces shim.
If present:
– Clean strainer.

– Install strainer.
The strainer is located in return line from ⇒ ATF cooler.
n AG. Volkswagen AG
The notches in the seal
olks
wmust
age align with the holes
does in the gearbox.
no
V t gu
by ara
– Insert new seal
ris
ed for ⇒ ATF pump. nte
tho eo
– Moisten
ss
aunew O-ring with ⇒ ATF and place on ⇒ ATF pump. ra
c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– Insert ⇒ ATF pump and press to stop by hand.

es, in part or in w

t to the co

– Tighten bolts evenly and diagonally.

Ensure that O-ring is not damaged in the process.
rrectness of i

Torque specification ⇒ Item 1 (page 113) bolt

l purpos

– Check dimension of clutch play ⇒ page 156 .

nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

– Insert plug with O-rings -arrow-.

p

cum
for

en
ng

t.
Installation position: lug engages in oil channel. Cop
yi Co
py
ht. rig
– Install ⇒ valve body with conductor strip ⇒ page 181 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

9. Dismantling and assembling gearbox 133

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Drive in cover using drift sleeve -40 - 20- .

– Install gearbox speed sender -G38- ⇒ Item 7 (page 46) .

– Push in ⇒ ATF overflow pipe -2- to stop and screw plug -3-
with new seal hand-tight into ATF pan -1-.

– Observe version of turbine shaft -arrow- ⇒ page 37 .

– Install ⇒ torque converter ⇒ page 37 .
– Install gearbox ⇒ page 79 .
– Fill with 3 litres of ⇒ ATF, check ⇒ ATF level and top up
⇒ page 100 . wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility

9.10 Installing exchange component

ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

134 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Thrust plate -VW 402-
♦ Press tool -VW 412-
AG. Volkswagen AG d
♦ Tube -VW 415 A- ksw
agen oes
not
Vol
by gu
d ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 135

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Tube -VW 418 A-

♦ Drift sleeve -40 - 20-
♦ Tube -3110-
♦ Assembly ring -3267-
♦ Gearbox mounting support
-3336-
♦ Torque wrench -
V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

All parts of the exchange component are exchange parts. Clean

an
itte

the replaced parts and pack them. Return all parts undamaged to y li
erm

the manufacturer. ab
ility
ot p

wit
, is n

Removing exchange component ⇒ page 118 through h re

⇒ page 124 .
hole

spec
es, in part or in w

– Set new O-ring (from exchange component) in planet carrier.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

136 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Place needle thrust bearing with shims (both from exchange

component) and planet carrier in input gear.
1- Input gear, installed in gearbox housing ⇒ page 111
2- New needle thrust bearing washer; insert smooth side into
input gear.
3- Insert new needle thrust bearing.
4- Insert new needle thrust bearing washer.
5- Install planet carrier with O-ring fitted.
Only gearboxes DFG, DMU, EPT

– Insert small sun gear with washer and needle thrust bearing
into planet carrier.
1- New needle thrust bearing (from exchange component)
2- New washer for needle thrust bearing (from exchange com‐
ponent)
3- Small sun gear
4- Planet carrier
AG. Volkswagen AG d
agen o
– Centre washer and needle
Vothrust
lksw bearing in “small sun
es ngear”.
ot g
y ua
db ran
Continued for all gearboxes
or
ise tee
th or
au ac
ss
– Set new washer -2- and new needle thrust bearing -1- (both
ce
e
nl

pt
du

from exchange component) on “small sun gear” in planet car‐

an
itte

rier -3-.
y li
erm

ab
ility

– Centre washer and needle thrust bearing in “small sun gear”.

ot p

wit
, is n

– Install shims and inner and outer plates of the -B1- included in
h re
hole

the exchange component (order ⇒ page 115 ).

spec
es, in part or in w

– Insert new pressure plate of -B1- with flat side facing plates.
t to the co
rrectness of i
l purpos

– Insert dished washer (from exchange component) with convex

nf
ercia

facing freewheel.
orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

9. Dismantling and assembling gearbox 137

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Preload rollers of new freewheel (from exchange component)

with assembly ring -3267- and insert freewheel.

– Installation position of freewheel: retaining wedge -arrow-

must be inserted in machined groove in gearbox housing.
– Install freewheel retaining ring -b- (from exchange compo‐
nent).
– Position gaps of retaining ring on freewheel retaining wedge
-arrow-.
– Insert baffle plate -2- in groove in gearbox housing in which ⇒
ATF breather hole -1- is located.

– Install retaining ring -a- (from exchange

gen AG
. Volkswagcomponent)
en AG
does
for sup‐
port tube of -B2-. Volkswa not
y gu
db ar
– Position gaps oof
ris retaining ring on freewheel retaining wedge
e an
tee
-arrow-. au
th or
a
ss c
– Install gearbox speed sender -G38- ⇒ Item 7 (page 46) .
ce
le
un

pt
an
d

– Check dimensions of -B1- ⇒ page 152 .

itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Insert components into gearbox housing starting with large

sun wheel down continuing to small input shaft.
rrectness of i

1- Large sun gear

l purpos

2- New washer for needle thrust bearing (from exchange com‐

ponent) - shoulder faces large sun gear.
nform
ercia

3- New needle thrust bearing (from exchange component)

m

a
com

ti

4- Large input shaft

on in
r
te o

thi

5- New needle thrust bearing (from exchange component)

s
iva

do
r

6- New needle bearing (from exchange component)

rp

cum
fo

en
ng

7- Small input shaft

t.
yi Co
Cop py
. rig
– Engage ⇒ parking lock.
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

138 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert screwdriver through holes of “large sun gear” to loosen

and tighten “bolt for small input shaft”.
– Remove screwdriver.

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– Set shim
aut -3- onto small input shaft shoulder -arrow-. or ac
ss
– Install bolt -1- for small input shaft with washer -2- and shim

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nl

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du

-3-.

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ab
Torque specification ⇒ Item 21 (page 115) bolt

ility
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– Check dimensions of planet carrier ⇒ page 149 .

wit
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hole

⇒ Clutches -K1- and -K3- in exchange component may be press‐

spec
ed together. Then they must be installed together.
es, in part or in w

t to the co
⇒ Clutches -K1- and -K3- may also be loosely pushed together in
some gearboxes.

rrectness of i
⇒ Clutches that are not pressed together:
l purpos

– Moisten new O-ring from exchange component with ⇒ ATF.

– Insert O-ring in recess in turbine shaft -arrow-.

nform
ercia

Further installation of exchange component

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(Figure shows pressed clutches -K1- and -K3-. The procedure

also applies to ⇒ clutches which are not pressed together.)
1 - Needle thrust bearing with washer
Moisten needle thrust bearing washer with ⇒ ATF so that bearing
adheres to -K3- during installation. Place washer of bearing onto
-K3-.
2 - 3rd and 4th gear clutch -K3-
– Place new needle thrust bearing with washer (both from ex‐
change component) onto 3rd and 4th gear clutch -K3-.

9. Dismantling and assembling gearbox 139

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Ensure that piston rings seat correctly on -K3-.

– Ensure that ends of piston rings are hooked together.
⇒ Clutches that are not pressed together:

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u or
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– Insert 3rd and 4th gear clutch -K3- with needle thrust bearing
s

ce
le

and washer.
un

pt
an
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itte

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• O-ring -1- is inserted in groove -arrow- and moistened with ⇒
erm

ab
ATF.

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is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
– Insert 1st to 3rd gear clutch -K1-.

o
cial p

f in
Pressed ⇒ Clutches:

form
mer

atio
If -K1- and -K3- are pressed together, then the two ⇒ clutches can
om

only be installed together. n

c

i
or

n thi
e

– Insert 1st to 3rd gear ⇒ clutch -K1- with 3rd and 4th gear clutch
t

sd
iva

-K3-.
o
pr

cum
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fo

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ng

If an exchange component is installed, only clutch play between

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⇒ clutches -K1/K3- and -K2- must be adjusted. Cop py
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For this purpose, coloured plastic shims are included in the ex‐
p by
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change component. Each of these shims has a different thick‐ Prote
cted AG.
agen
ness.
For the procedure for measuring the play and selecting shims,
see ⇒ page 153 .
Use new ⇒ clutches -K1/K3- and -K2- from exchange component
to make adjustments.

140 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert determined shims -arrow- into -K1-.

Up to 3 shims may be installed.

– Insert new reverse clutch -K2- (from exchange component).

– Insert support tube for -B2- plate set so that support tube
groove engages in freewheel wedge.
Before continuing assembly
There are two versions of the -B2- ⇒ brake.

⇒ Brake with corrugated spring -A-

Here, the last outer plate also serves as a “shim”. This outer plate
is available in various thicknesses.
⇒ Brake with retaining ring -B-
In this version, a shim and a 3 mm thick outer plate are placed
under the retaining ring. agen
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⇒ Brake -B2- with corrugated spring d by V ua
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The thickness of the last outer plate
tho determines the play of ⇒ or
au ac
brake -B2- only in gearboxessswith built-in corrugated washer.
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ility
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es, in part or in w

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te

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Cop py
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Prote AG.

9. Dismantling and assembling gearbox 141

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install new plates for -B2- (from exchange component) as de‐

scribed below:
– First insert a new 3 mm thick outer plate.
– Place three new spring caps in outer plate.
– Insert new compression springs -arrows-.
– Insert all but last outer plate.
– Place new three spring caps onto compression springs.
– Insert last measured outer plate (from exchange component).
– Insert new corrugated washer.
Further installation of exchange component ⇒ page 142 .
⇒ Brake -B2- with retaining ring

In all gearboxes with retaining ring -b-, the last outer plate is also
always 3 mm thick. The play of ⇒ brake -B2- is determined by
shim -a- that is placed on retaining ring -b-. There is no corrugated
washer.
Install new plates for -B2- (from exchange component) as descri‐
bed below:
– First insert a new 3 mm thick outer plate.
– Place three new spring caps in outer plate.
– Insert new compression springs -arrows-.
– Insert all but last outer plate.
– Place new three spring caps onto compression springs.
AG. Volkswagen AG d
– Insert last outer plate, 3 mm thick. agen oes
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– Insert new measured shim -a- (from exchange ocomponent).
ris
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– Set new retaining ring -b- onto shim. Smooth
ss a side faces shim. c ce
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nl

Further installation of exchange component

pt
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If present:
erm

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ility
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– Clean strainer.
wit
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h re
hole

– Install strainer.
spec
es, in part or in w

The strainer is located in return line from ⇒ ATF cooler.

t to the co

– Insert new seal for ⇒ ATF pump (from exchange component),

observing positions of all drillings.
rrectness of i

– Moisten new O-ring (from exchange component) with ⇒ ATF

l purpos

and place on ⇒ ATF pump.

nform
mercia

at
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ion
c

in t
or

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ate

do
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cum
for

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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

142 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Moisten new ⇒ ATF pump (from exchange component) with ⇒

ATF, insert and press to stop by hand.
Ensure that O-ring is not damaged in the process.
– Tighten bolts evenly and diagonally. AG. Volkswagen AG d
agen oes
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Torque specification ⇒ Item 1 (page 113) bolt d byV
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– Check dimension of clutch play ⇒ page 156 ut .
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s

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un

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itte

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pe

ility
ot

wit
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– Moisten plug with 2 new O-rings (from exchange component)

h re
with ⇒ ATF and insert in gearbox housing.
hole

spec
es, in part or in w

Installation position: lug -arrow- engages in oil channel.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

– Secure spool valve -arrow- so that it cannot fall out.

thi
s
iva

do
r

– Install new ⇒ valve body with spool valve, new operating rod
rp

cum
fo

and new steel spring with bolt for spool valve operation (from

en
ng

t.
exchange component) ⇒ page 181 .
yi Co
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– Install conductor strip with gearbox oil temperature sender - rig ht
py by
G93- (not included in exchange component) and O-ring for
co Vo
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cted
cable aperture in gearbox housing (from exchange compo‐
agen
Prote AG.
nent) ⇒ page 190 .
– Install new strainer with new seal (from exchange component)
⇒ page 180 .
– Install pan with gasket and spacer bushes ⇒ page 178 .

– Screw in overflow pipe -2- ⇒ Item 2 (page 181) overflow pipe.

– Screw in plug -3- hand-tight with new oil seal.

9. Dismantling and assembling gearbox 143

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Drive in new cover using drift sleeve -40 - 20- .

– Install gearbox speed sender -G38- ⇒ Item 7 (page 46) .

– Now check whether there is a sleeve bearing in turbine shaft

-arrow- ⇒ page 7 .
– Before inserting ⇒ torque converter, check whether ⇒ torque
converter has correct code.
agen
ADetermining code
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– Install ⇒ torque dconverter
by
V
⇒ page 42 . ua
ran
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ris tee
– Install gearbox
au
tho ⇒ page 79 . or
ac
ss
– Fill with 3 litres of ⇒ ATF ⇒ page 103 , check ⇒ ATF level and
ce
le
un

top up ⇒ page 100 .

pt
an
d
itte

y li

– Check oil in final drive ⇒ page 198 .

rm

ab
pe

ility
ot

wit
, is n

h re

9.11 Overview - all ⇒ planetary gearbox adjustments

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
r
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
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cted agen
Prote AG.

144 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
. Volkswagen AG
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I - Planet carrier Vol
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not
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❑ A - Shim ris
ed
b ara
nte
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❑ Determining thickness
au
th
ra
⇒ Adjusting planet
ss carri‐ c

ce
le
er ⇒ page 146 . un

pt
an
d
itte

II - Reverse gear brake -B1-

y li
erm

ab
❑ B - Shim.

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wit
❑ Determining thickness
is n

h re
⇒ Adjusting reverse
ole,

spec
gear brake -B1-
urposes, in part or in wh

⇒ page 150 .

t to the co
III - Clutch play
❑ C - Shim.

rrectne
❑ Determining thickness
⇒ Adjusting clutch play

ss
between -K1- and -K2-

o
cial p

f
⇒ page 153 .

inform
mer

IV - 2nd and 4th gear brake -

atio
B2-
om

n
c

i
❑ D - Outer plate or shim.
or

n thi
te

sd
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❑ Determining thickness
iv

o
pr

c
⇒ Adjusting 2nd and 4th

um
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fo

gear brake -B2-

en
ng

t.
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⇒ page 157 .
Co
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cted agen
Prote AG.

9. Dismantling and assembling gearbox 145

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9.12 Adjusting planet carrier

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Measuring tool -VW 382-
♦ Dial gauge

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spec
es, in part or in w

t to the co
rrectness of i

Overview - components for adjusting planet carrier

l purpos

– Install components for adjusting planet carrier in gearbox

housing without shim ⇒ Item 18 (page 147) .
nf
ercia

orm
m

atio
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te

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Prote AG.

146 Rep. Gr.37 - Controls, housing

 AG. Volkswagen AG d
agen oes
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V gu
d by ara
orise nte Passat 1997 ➤
h e
aut 4-speed oautomatic
ra
c
gearbox 01N - Edition 10.2005
ss

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1 - Input gear

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itte
❑ Do not remove to adjust

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planet carrier.

ility
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❑ Removing and installing

wit
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input gear or needle

h re
hole

thrust bearing for planet

spec
carrier ⇒ page 208
es, in part or in w

t to the co
2 - Needle thrust bearing
washer

rrectness of i
❑ Insert smooth side in in‐
put gear.
l purpos

3 - Needle thrust bearing

nform
ercia

4 - Needle thrust bearing

washer
m

at
om

io
5 - O-ring

n
c

in t
or

❑ Insert into planet carrier

his
ate

⇒ Assembling planet

do
priv

c
carrier ⇒ page 125 .

um
for

en
ng

❑ Always renew
t.
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Cop py
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6 - Planet carrier opyri
gh by
Vo
ht
by c lksw
7 - Gearbox housing Prote
cted AG.
agen

❑ With input gear and nee‐

dle thrust bearing
❑ Needle thrust bearing
remains in input gear
❑ If needle thrust bearing
is damaged ⇒ Remov‐
ing and installing input
gear ⇒ page 208
8 - Small sun gear
❑ Can be removed from
planet carrier only in
gearboxes “DFG”,
“DMU” and “EPT”.
9 - Washer
10 - Needle thrust bearing
11 - Large sun gear
12 - Washer
❑ Insert into large sun gear ⇒ Assembling planetary gearbox ⇒ page 125 .
13 - Needle thrust bearing
14 - Large input shaft
15 - Needle thrust bearing
16 - Needle bearing
17 - Small input shaft
18 - Shim
❑ Do not install when adjusting planet carrier.
19 - Washer
20 - Small drive shaft bolt, 30 Nm

9. Dismantling and assembling gearbox 147

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Determining shim -A-

– Observe general repair instructions ⇒ page 11 .
– Install all components ⇒ Item 2 (page 147) to
⇒ Item 6 (page 147) and ⇒ Item 8 (page 147) to
⇒ Item 17 (page 147) in gearbox housing to adjust planet car‐
rier ⇒ Item 2 (page 147) .
– Engage ⇒ parking lock.

– Insert screwdriver through holes of “large sun gear” to loosen

and tighten “bolt for small input shaft”.
– If ⇒ parking lock cannot be engaged, also block large input
shaft with a second screwdriver.

AG. Volkswagen AG d
agen oes
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– Install bolt for small input shaft -1- with washer -2-uthowithout
r eo
ra
shim. ss a c
ce
e

Torque setting ⇒ Item 20 (page 147)

nl

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an
itte

– Remove screwdriver. y li
erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

148 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Set up measuring instrument with dial gauge tip centred of bolt

head with 1 mm preload.
– Set dial gauge to “0”.
– Press small input shaft up and take reading.
Example: Measured value 2 mm
– Ascertain thickness of shim according to table and determine
part No. from parts catalogue.
Table of shims:
Measured value (mm) Shims (mm)
1.26 … 1.35 1.0
1.36 … 1.45 1.1
1.46 … 1.55 1.2
1.56 … 1.65 1.3
1.66 … 1.75 1.4
1.76 … 1.85 1.5
1.86 … 1.95 1.6
1.96 … 2.05 1.7
2.06 … 2.15 1.8
2.16 … 2.25 1.9
2.26 … 2.35 1.0 + 1.0
2.36 … 2.45 1.0 + 1.1
2.46 … 2.55 1.1 + 1.1
2.56 … 2.65 1.1 + 1.2
2.66 … 2.75 1.2 + 1.2
2.76 … 2.85 1.2 + 1.3
2.86 … 2.95 . 1.3
Volks+wa
1.3
ge
2.96 … 3.05 wagen AG 1.3 + 1.4n AG doe
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3.06 … 3.15 edb 1.4 + 1.4 ara
3.16 … 3.25 thoris
1.4 + 1.5 nte
eo
u ar ac
Example: ss
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e
nl

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Measured value 2.00 mm = insert 1.7 mm thick shim.

an
itte

y li
erm

ab

– Remove bolt for small input shaft.

ility
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wit
, is n

– Set determined shim -3- on small input shaft -arrow-.

h re
hole

spec

– Tighten bolt for small input shaft -1- with washer -2-.
es, in part or in w

t to the co

Torque setting ⇒ Item 20 (page 147)

– Check dimensions of planet carrier.
rrectness of i

Checking dimensions of planet carrier

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

9. Dismantling and assembling gearbox 149

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert dial gauge in -VW 382/7- and place tip on bolt of small
input shaft.
– Move small input shaft up and down and read play on dial
gauge.
Play:
min. = 0.23 mm
max. = 0.37 mm
If the planet carrier has been adjusted with reverse gear brake -
B1- and freewheel removed, then install reverse gear brake -B1-
before installing planet carrier ⇒ Assembling planetary gearbox
⇒ page 125 .

9.13 Adjusting reverse gear brake -B1-

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Thrust plate -VW 402-
♦ Depth gauge
♦ Straightedge
♦ Feeler gauge

AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl

pt
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an
itte

y li
erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

Overview - components for adjusting reverse gear brake -B1-

p

cum
for

en
ng

t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

150 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Gearbox housing
❑ With input gear and
planet carrier installed.
2 - Shim
❑ 1 or 2 shims may be in‐
stalled.
3 - Outer plate -B1-
❑ Quantity ⇒ page 7 .
4 - Inner plate -B1-
❑ Quantity ⇒ page 7 .
5 - Pressure plate
AG. Volkswagen AG d
❑ Install with flat side fac‐ ksw
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ing plates. byV
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❑ Parts are allocated ac‐ horis nte
eo
cording to gearbox codes aut ra
c
letters. s

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6 - Dished spring

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❑ Convex side faces free‐
erm

ab
ility
wheel.
ot p

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7 - Freewheel with -B1- piston

h re
hole

spec
Before removing or installing
es, in part or in w

freewheel, remove ⇒ valve

t to the co
body, take out plug
⇒ page 181 and remove gear‐
box speed sensor -G38-

rrectness of i
⇒ Item 7 (page 46) .
l purpos

8 - Retaining ring

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

Determining thickness of shim -B-

um
for

en
ng

t.
yi
– Observe general repair instructions ⇒ page 11 .
Co
Cop py
ht. rig
Shim thickness depends on gap “x” and is to be selected from
rig ht
py by
o Vo
table ⇒ page 152 . by c lksw
cted agen
Prote AG.
X = K + l2 - m
B - Shim
X - Gap
l - Position of piston in freewheel
m - Height of plate set including pressure plate
K - Constant value = 30.6 mm
“K” is determined by structural height in gearbox housing and is
not adjustable.
Calculating I:

9. Dismantling and assembling gearbox 151

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Press piston in direction of arrow to stop.

– Place straightedge -A- on outer race of freewheel.
– Measure to inner edge of piston with depth gauge -B-.
Example:
n AG. Volkswagen AG do
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Measured value = yV
olks 51.8 mm ot g
ua
d b
- Straightedge = orise -48.2 mm ran
tee
th or
Determined value of l =au 3.6 mm ac
ss

ce
e
Determining m: nl

pt
du

an
itte

y li
erm

ab
ility
– Place straightedge -A- on pressure plate.
ot p

wit
, is n

– Compress plate set including pressure plate in direction of ar‐

h re
hole

row and measure thickness of plate set with depth gauge

spec
-B-.
es, in part or in w

t to the co
Example:
Measured value = 77.2 mm

rrectness of i
- Straightedge = -48.2 mm
l purpos

Determined value m = 29.0 mm

nf
X = K + l2 - m
ercia

orm
m

= 30.6 + 3.62 - 29.0 = 3.4 mm

atio
om

n in
c

– Determine size of shim according to table:

or

thi
te

sd
a

Table of shims:
iv

o
r
rp

cu
o

m
f

Gap-x- (mm) Shims (mm)

en
ng

t.
yi Co
op
2.36 … 2.45 1.0
C py
t. rig
gh
2.46 … 2.5 1.1
ht
pyri by
Vo
2.56 … 2.65 1.2
co lksw
by
cted agen
Prote AG.
2.66 … 2.75 1.3
2.76 … 2.85 1.4
2.86 … 2.95 1.5
2.96 … 3.05 1.6
3.06 … 3.15 1.7
3.16 … 3.25 1.8
3.26 … 3.35 1.9
3.36 … 3.45 1.0 + 1.0
3.46 … 3.55 1.0 + 1.1
3.56 … 3.65 1.1 + 1.1
3.66 … 3.75 1.1 + 1.2
3.76 … 3.85 1.2 + 1.2
3.86 … 3.95 1.2 + 1.3
3.96 … 4.05 1.3 + 1.3
4.06 … 4.15 1.3 + 1.4
4.16 … 4.25 1.4 + 1.4
– Ascertain thickness of shim according to table and determine
part No. from parts catalogue.
– After determining shim for -B1-, check dimensions.
Checking dimensions for reverse gear brake -B1-
– Install parts up to freewheel and secure with retaining ring ⇒
Assembling planetary gearbox ⇒ page 125 .

152 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Measure play between plates with feeler gauge “A”.

Play:
min. = 1.25 mm
max. = 1.55 mm

9.14 Adjusting clutch play between -K1- and -K2-

Special tools and workshop

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
♦ Gearbox support -VW 353-
♦ Universal dial gauge brack‐
et -VW 387-
♦ Depth gauge
♦ Straightedge
♦ Dial gauge

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

– To adjust clutch play, install components without shim

o

n in
c

⇒ Item 6 (page 154) ⇒ Assembling planetary gearbox

or

thi
e

⇒ page 125 .
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 153

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Gearbox housing
❑ ⇒ Planetary gearbox in‐
stalled up to small input
shaft ⇒ Assembling
planetary gearbox
⇒ page 125 .
2 - Needle thrust bearing with
washer
❑ Needle thrust bearing
faces small input shaft
❑ Washer faces towards -
K3-.
3 - 3rd and 4th gear clutch -K3-
with turbine shaft
❑ ⇒ Clutches -K1- and -
K3- may be pressed to‐
gether in some gearbox‐
es.
❑ There are two different
versions ⇒ page 37 .
4 - O-ring
❑ Always renew
5 - 1st to 3rd gear clutch -K1-
6 - Shims
❑ Do not install when ad‐
justing clutch play.
❑ Up to 3 shims can be in‐
stalled.
7 - Reverse gear clutch -K2-
❑ Does not need to be in‐
stalled for determining
the shim(s). AG. Volkswagen AG d
agen oes
olksw not
❑ Install for check meas‐ ed by
V gu
ara
urement. horis nte
eo
aut ra
ss c
ce
e
nl

pt

Determining thickness of shim -C-

du

an
itte

y li
erm

– Observe general repair instructions ⇒ page 11 .

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
154
agen
Prote AG.
Rep. Gr.37 - Controls, housing
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Prerequisites:
• Planet carrier is installed and adjusted ⇒ Assembling planetary
gearbox ⇒ page 125 , Installing exchange component
⇒ page 134
• Gearbox housing must be turned inaassembly
n AG. Volkstand
swagenwith
AG doinput
w ge
gear downwards for checking Vdimensions,
olks as shown in es not g
y
⇒ Item 1 (page 154) . se
db ua
ran
ri tee
ho
Determining shim -C- aut or
ac
ss
C - Shim

ce
le
un

pt
an
d
itte

1 - ⇒ ATF pump

y li
erm

ab
2 - Reverse gear clutch -K2-

ility
ot p

wit
is n

3 - 1st through 3rd gear clutch -K1-

h re
ole,

spec
4 - 3rd and 4th gear clutch -K3-
urposes, in part or in wh

t to the co
– Calculate thickness of shim. Determine gap “x” and calculate
shim thickness.
Gap x = a - b

rrectne
Calculating a:

ss o
• Gearbox housing must be turned in assembly stand with input
cial p

f i
gear downwards for checking dimensions, as shown in

nform
⇒ Item 1 (page 154) .
mer

atio
om

n
c

– Place straightedge -A- on gearbox housing.

i
or

n thi
te

sd
a

– Press -K1- downwards in direction of arrow and measure into

iv

o
pr

-K1- using depth gauge -B-. cum

r
fo

en
ng

t.
Example:
yi Co
Cop py
ht. rig
Measured value 1 = 88.5 mm rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Measure with depth gauge -B- to pump flange on gearbox

housing.
Example:
Measured value 2 = 34.3 mm
Measured value 1 = 88.5 mm
- Measured value 2 = -34.3 mm
Calculated value a = 54.2 mm
= Value measured from pump flange/gearbox housing into -K1-.
Calculating b:
– Place new paper gasket on ⇒ ATF pump.

9. Dismantling and assembling gearbox 155

 . Volkswagen AG
gen AG does
Passat 1997 ➤ olks
wa not
yV gu
4-speed automatic gearbox 01N - Edition 10.2005 ised b ara
nte
or h eo
ut ra
– Place straightedge -B- on top of stator support -arrow-
ss and
a c
measure with depth gauge -A- to gasket of pump flange.

ce
le
un

pt
an
d
Example:

itte

y li
erm

ab
ility
Measured value = 70.5 mm

ot p

wit
is n
- Straightedge = -19.5 mm

h re
ole,
Calculated value b = 51.0 mm

spec
urposes, in part or in wh

t to the co
Gap x = a - b
= 54.2 mm - 51.0 mm = 3.2 mm

rrectne
– Determine shims according to table ⇒ page 156 .
– Check clutch play dimension after installing ⇒ ATF pump

ss
⇒ page 156 .

o
cial p

f inform
Table of shims:
mer

atio
m

Gap-x- (mm) Thickness of re‐ Colour of required

o

n
c

quired shims (mm) shims

i
or

n thi
te

sd
a

… 2.54 1.4 White

iv

o
pr

2.55 … 3.09 1+1 Blue + blue

cum
r
fo

3.10 … 3.49 1.2 + 1.2 Green + green

en
ng

t.
yi Co
op
3.50 … 3.89 1.4 + 1.4 White + white C py
t. rig
3.90 … 4.29 1.6 + 1.6 Black + black gh ht
yri by
4.30 … 4.69 1.8 + 1.8 Grey + grey
op Vo
by c lksw
cted agen
4.70 … 5.04 1.2 + 1.2 + 1.6 Green + green +
Prote AG.

5.05 … 5.25 1.2 + 1.2 + 1.8 black

Green + green +
grey
– Ascertain thickness of shim according to table and determine
part No. from parts catalogue.
Shims have different thicknesses.
Blue = 1.0 mm
Green = 1.2 mm
White = 1.4 mm
Black = 1.6 mm
Grey = 1.8 mm
In the previous example, it was calculated that x = 3.2 mm. Con‐
sequently, two green shims would be used in this example.
If an exchange component is used:
The exchange component contains shims of various colours and
thicknesses to adjust the play between -K1- and -K2-.
Measurement to check clutch play
– The clutch play cannot be measured until the ⇒ ATF pump has
been installed.
– Attach dial gauge holder to gearbox housing and place dial
gauge on turbine shaft with 1 mm preload.

156 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
n AG. Volkswagen A
– Move turbine shaft up and down
olks
wand
age read play on dial
G do
gauge.
es n
o
yV t gu
Play: db ara
rise nte
tho eo
min. = 0.5 mm ss
au ra
c

ce
e
max. = 1.2 mm
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
9.15 Adjusting 2nd and 4th gear brake -B2-

rrectness of i
l purpos

Special tools and workshop

equipment required

nform
ercia

♦ Support plate -VW 309-

m

at
♦ Support clamp -VW 313-
om

ion
c

in t
r

♦ Gearbox support -VW 353-

o

his
ate

do
riv

♦ Setting gauge -3459-

p

cum
for

en
g

♦ Depth gauge
n

t.
yi Co
op py
♦ Straightedge
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

These instructions for adjustment apply only to gearboxes in

which a shim and a retaining ring are installed in ⇒ brake -B2-
⇒ Item 11 (page 158) and ⇒ Item 12 (page 158) .
In these gearboxes, the play of ⇒ brake -B2- is determined by the
thickness of the shim.
In some gearboxes, a corrugated washer is installed on the last
outer plate instead of the retaining ring.

9. Dismantling and assembling gearbox 157

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

The play of brake -B2- is then determined by the thickness of the

last outer plate.
Instructions for adjusting these gearboxes with corrugated wash‐
er instead of shim and retaining ring ⇒ page 161 .
– Install components for adjusting without shim
⇒ Item 11 (page 158) , without last outer plate
⇒ Item 10 (page 158) and without spring caps
⇒ Item 6 (page 158) .

1 - Gearbox housing
2 - Retaining ring
❑ For support tube.
3 - Support tube -B2-
❑ Parts are allocated aac‐ n AG. Volkswagen AG do
w ge
cording to gearbox
olks code es n
ot g
yV
letters. sed b ua
ran
ir tee
❑ Insertauso that recess on
tho
or
ac
support
ss tube engages in
freewheel retaining ce
le
un

pt
wedge. an
d
itte

y li
erm

ab
4 - Outer plate -B2-
ility
ot p

❑ 3 mm thick.
wit
is n

h re

5 - Spring cap
ole,

spec
urposes, in part or in wh

❑ Install after installing

t to the co

first outer plate

⇒ Item 4 (page 158) .
6 - Spring cap
rrectne

❑ Do not install when ad‐

justing -B2-.
ss o

❑ Install before installing

cial p

f in

last outer plate.

form
mer

7 - Spring
atio
om

❑ Parts are allocated ac‐

c

i
or

cording to gearbox code

thi
te

sd
a

letters.
iv

o
pr

cum
r
fo

8 - Inner plate -B2-

en
ng

t.
yi Co
❑ Quantity ⇒ page 7 . t. Cop py
rig
gh
❑ Parts are allocated ac‐
ht
pyri by
Vo
cording to gearbox code
co lksw
by
cted agen
letters. Prote AG.

9 - Outer plate -B2-

❑ Always install 2 mm thick outer plates.
❑ Quantity ⇒ page 7 .
10 - Outer plate -B2-
❑ 3 mm thick.
❑ Do not install when adjusting -B2-.
11 - Shim
❑ Do not install when adjusting -B2-.
12 - Retaining ring
❑ Insert with smooth side facing last inner plate ⇒ Item 8 (page 158) when adjusting -B2-.

158 Rep. Gr.37 - Controls, housing

 n AG. Volkswagen AG do
lkswage es n
byV
o
Passat
ot g
ua 1997 ➤
ed ran
4-speed
horis automatic gearbox 01N - Edition 10.2005
tee
ut or
a ac
ss
9.15.1 Calculating shim(s)

ce
e
nl

pt
du

an
itte
– Observe general repair instructions ⇒ page 11 .

y li
erm

ab
The thickness of the shim(s) depends on gap x. Observe the fol‐

ility
ot p
lowing formula to do this:

wit
, is n

h re
hole
Gap x = a - b - 2.65 mm

spec
es, in part or in w
To help in the understanding of this formula, the measuring points

t to the co
are shown in the figure. Setting tool -3459- , which exerts a force
-F- onto the plate set via the retaining ring, is not illustrated.

rrectness of i
Calculating dimension -a- ⇒ page 159 .

l purpos
Calculating dimension -b- ⇒ page 160 .
2.65 mm - the amount for settling is taken into account by force

nf
ercia
-F-.

orm
m

atio
1- ⇒ ATF pump
om

n in
c

2- Retaining ring
or

thi
te

sd
iva

3- -B2- plates without last outer plate

o
r
rp

cu
o

m
f

4- Support tube

en
ng

t.
yi Co
op
First outer plate -arrow- and last outer plate (do not install to
C py
t. rig
gh
measure!) are always 3 mm thick.
ht
pyri by
Vo
co lksw
by
cted
Calculating dimension a:
agen
Prote AG.

Assemble ⇒ planetary gearbox up to the last -B2- inner plate

⇒ page 125 . The last outer plate and shim are not to be installed.

– Set smooth side of retaining ring on last inner plate.

– Place -3459- on retaining ring and turn so that the 3 clips align
with the 3 holes for ⇒ ATF pump.
– Bolt -3459- to flange for ⇒ ATF pump with 5 Nm torque.
This presses the plate set for -B2- together for the measurement.

9. Dismantling and assembling gearbox 159

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Measure from pump flange of gearbox housing -arrow- to

-3459- with depth gauge.
Dimension -a- = height of -3459- in mm - measured value
Example:
Height of -3459- gen AG
. V=
olkswagen AG 60.0 mm
swa does
- Measured value yV
olk = -32.7
not mm
gu
db ara
Calculated value a horise
= 27.3 mmntee
t or
au ac
– Note calculated
ss value a.

ce
e
nl

pt
– Remove -3459- .
du

an
itte

y li
erm

– Remove retaining ring.

ab
ility
ot p

Calculating dimension b:

wit
, is n

h re
– Push piston into ⇒ ATF pump to stop.
hole

spec
es, in part or in w

– Place new paper gasket on ⇒ ATF pump.

t to the co
– Place straightedge -B- on stator support -arrow- and measure
with depth gauge -A- to gasket of pump flange.

rrectness of i
Example:
l purpos

Measured value = 39.8 mm

nform
ercia

- Straightedge = -19.5 mm
m

at
Calculated value b = 20.3 mm
om

ion
c

in t
r

– Note calculated value b.

o

his
ate

do
riv

Gap x = a - b - 2.65 mm
p

cum
for

en
g

Gap x = 27.3 - 20.3 - 2.65 mm = 4.35 mm

n

t.
yi Co
op py
– Determine thickness of shim(s) according to table:
t. C rig
gh ht
pyri by
Vo
Table of shims:
o
by c lksw
cted agen
Prote AG.
Gap-x- (mm) Shims (mm)
3.25 … 3.50 1.0
3.51 … 3.75 1.25
3.76 … 4.00 1.50
4.01 … 4.25 1.75
4.26 … 4.50 1.00 + 1.00
4.51 … 4.75 1.00 + 1.25
4.76 … 5.00 1.25 + 1.25
5.01 … 5..25 1.25 + 1.50
5.26 … 5.50 1.50 + 1.50
5.51 …5.75 1.50 + 1.75
5.76 …6.00 1.75 + 1.75
– Ascertain thickness of shim(s) according to table and deter‐
mine part No. from parts catalogue. In this example, two shims
must be installed (each 1 mm thick).
– Place three spring caps onto compression springs.
– Insert last outer plate, 3 mm thick.

160 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install correct shim(s) -a-.

– Place retaining ring -b- onto shim(s). Smooth side faces shim.
– Further installation instructions are described from
⇒ page 133 .

9.15.2 Adjusting 2nd and 4th gear brake -B2-

These instructions for adjustment apply only to gearboxes in
which a corrugated washer is installed on the last outer plate in ⇒
brake -B2- ⇒ Item 10 (page 162) and ⇒ Item 11 (page 162) .
These gearboxes have the codes:
DFG, DFH, DFK
In these gearboxes, the play of ⇒ brake -B2- isagdetermined
en AG. V
olkswby
agethe
n AG d
oes
thickness of the last outer plates). Volksw not
g y ua
db ran
– Install components for adjusting riswithout corrugated washer
e
tee
⇒ Item 11 (page 162) , without
utholast outer plate or
sa ac
⇒ Item 10 (page 162) and swithout spring cap
ce
le

⇒ Item 6 (page 162) .

un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 161

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Gearbox housing
2 - Retaining ring
❑ For support tube.
3 - Support tube -B2-
❑ Parts are allocated ac‐
cording to gearbox code
letters.
❑ Insert so that recess on
support tube engages in
freewheel retaining
wedge.
4 - Outer plate -B2-
❑ 3 mm thick.
5 - Spring cap
❑ Install after installing
first outer plate
⇒ Item 4 (page 162) .
6 - Spring cap
❑ Do not install when ad‐
justing -B2-.
❑ Install before installing
last outer plate.
7 - Spring
❑ Parts are allocated ac‐
cording to gearbox code
letters.
8 - Inner plate -B2-
❑ Quantity ⇒ page 7 .
❑ Parts are allocated ac‐
cording to gearbox code
letters.
AG. Volkswagen AG d
agen oes
9 - Outer plate -B2- Vol
ksw not
gu
by ara
❑ Always install 2 mm thick outer plates. rised
nte
ho eo
❑ Quantity ⇒ page 7 . sa
ut ra
c
s
10 - Outer plate -B2-
ce
e
nl

pt
du

an

❑ Do not install when adjusting -B2-.

itte

y li
erm

ab

❑ 2 outer plates can be installed for adjustment.

ility
ot p

wit

11 - Corrugated washer
, is n

h re

❑ Do not install when adjusting -B2-.

hole

spec
es, in part or in w

t to the co

Calculating thickness of last outer plate -D-

rrectness of i

The thickness of the last outer plate(s) depends on gap “x”. Ob‐
serve the following formula to do this:
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

162
cop Vo
by lksw
Rep. Gr.37 - Controls, housing Prote
cted AG.
agen
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Gap x = a - b -3.6 mm
The figure shows ⇒ brake -B2- installed in the gearbox. Setting
tool -3459- , which exerts a force onto the plate set, is not illus‐
trated.
Calculating dimension -b- ⇒ page 163 .
3.6 mm - the amount for settling is taken into account by the force
of the setting tool -3459- .
First outer plate -arrow- is always 3 mm thick.
Calculating dimension a:
Assemble ⇒ planetary gearbox up to the last -B2- inner plate
⇒ page 125 . The last outer plate, the last 3 spring caps and the
corrugated washer are not to be installed!
– Place -3459- on last inner plate and turn so that the 3 clips
align with the 3 holes for ⇒ ATF pump.
– Bolt -3459- to flange for ⇒ ATF pump with 5 Nm torque.
This presses the plate set for -B2- together for the measurement.

– Measure from pump flange of gearbox housing -arrow- to

-3459- with depth gauge.
Dimension -a- = height of -3459- in mm - measured value
Volkswa n AG. gen AG
wage does
Example: Volks not
gu
by ara
ed nte
Height of 3459 horis = 60.0 mm eo
ut ra
- Measured value ss
a
= -29.8 mm c ce
le

Calculated value a = 30.2 mm

un

pt
an
d
itte

y li

– Note calculated value a.

erm

ab
ility
ot p

– Remove -3459- .
wit
is n

h re

Calculating dimension b:
ole,

spec
urposes, in part or in wh

– Push piston into ⇒ ATF pump to stop.

t to the co

– Place new paper gasket on ⇒ ATF pump.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Dismantling and assembling gearbox 163

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Place straightedge -B- on stator support -arrow- and measure

with depth gauge -A- to gasket of pump flange.
Example:
Measured value = 40.1 mm
- Straightedge = -19.5 mm
Calculated value b = 20.6 mm
– Note calculated value b.
Gap x = a - b -3.6 mm
Gap x = 30.2 -20.6 -3.6 mm = 6.0 mm
– Determine thickness of outer plate(s) according to table:
Table of outer plates:
Gap“x” (mm) Plate (mm)
4.25 … 4.49 2.75
4.50 … 4.74 3.00
4.75 … 4.99 3.25
5.00 … 5.24 3.50
5.25 … 5.49 3.75
5.50 … 5.74 2.00 + 2.00
5.75 … 5.99 2.00 + 2.25
6.00 … 6.24 2.25 + 2.25
6.25 … 6.49 2.25 + 2.50
6.50 … 6.74 2.50 + 2.50
6.75 … 7.00 2.50 + 2.75
– Ascertain thickness of necessary outer plate(s) according to
table and determine part No. from parts catalogue. In this ex‐
ample, two outer plates must be installed (each 2.25 mm
thick).
olkswagen AG
en AG. V
– Place three spring caps onto compression springs.
olks
wag does
not
yV gu
db ara
– Install calculated last outer plate(s). rise nte
tho eo
– Insert corrugated washer. au ra
c
ss
ce
le

– Further installation instructions are described from

un

pt
an
d

⇒ page 133 .
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

164 Rep. Gr.37 - Controls, housing

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

38 – Gears, control
1 Dismantling and assembling ⇒ ATF pump
– Observe general repair instructions ⇒ page 11 .
Replacement ⇒ ATF pump parts and the pump itself are allocated
according to gearbox code.
Removing ⇒ ATF pump ⇒ page 118
Installing ⇒ ATF pump ⇒ page 125

1 - Piston ring
❑ Removing and installing
⇒ page 166
❑ Check for proper seat‐
ing ⇒ page 166 .
2 - Piston ring
❑ Removing and installing
⇒ page 166
❑ Check for proper seat‐
ing ⇒ page 166 .
3 - Piston ring
❑ Removing and ainstalling
gen AG
. Volkswagen AG
does
⇒ page 166 olksw not
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❑ Check oris for proper seat‐
e nte
ing
au ⇒ page 166 .
th eo
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4 - Thrust washer
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an
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5 - Piston
itte

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❑ Sealing lips are vulcan‐

ility
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ised to piston.
wit
is n

❑ Moisten sealing lips with

h re
ole,

⇒ ATF before installing.

spec
urposes, in part or in wh

❑ Turn piston slightly

t to the co

when installing.
6 - Bolt, 10 Nm
rrectne

❑ Then turn 45° further.

7 - Stator support
ss o
cial p

8 - Outer gear
inform

❑ Manufacturer's marking
mer

atio

-arrow- faces stator sup‐

om

port.
n
c

i
or

n thi

❑ If outer gear is incorrect‐

te

sd
va

ly installed, the ⇒ ATF

i

o
pr

pump may not operate freely in the installed position.

um
r
fo

en
ng

t.
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9 - Inner gear
Co
Cop py
t. rig
❑ Larger groove faces stator support.
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pyri by
Vo
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10 - Housing for ⇒ ATF pump
Prote
cted AG.
agen

11 - O-ring
❑ Always renew
12 - ⇒ Torque converter seal
❑ Removing and installing ⇒ page 41

1. Dismantling and assembling ATF pump 165

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Removing and installing piston ring

Removing
– Compress piston ring and release it.
– Expand piston ring on both sides and remove; do not twist out
of groove on one side.
Installing
– Place piston ring in groove.
– To hook ends together, press sides of ring in and guide ends
over one another.

Checking seating of piston rings AG. Volkswagen AG d

agen oes
ksw not
– Ensure that ends of piston rings are hooked together. by Vol
gu
ara
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un

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d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

166 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

2 Dismantling and assembling freewheel with -B1- piston

– Observe general repair instructions ⇒ page 11 .

1 - Rollers
❑ Installing ⇒ page 168
2 - Springs
❑ Installing ⇒ page 168
3 - Cage
❑ Removing and installing
⇒ page 167
❑ Installation position
⇒ page 168
4 - Outer ring
5 - Piston
❑ Sealing lips are vulcan‐
ised to piston.
❑ Moisten sealing lips with
⇒ ATF before installing.
❑ Turn piston slightly
when installing.
❑ Installation position
⇒ page 168

n AG. Volkswagen AG do
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ss
ce
e
nl

pt
du

an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec

Removing and installing cage

es, in part or in w

t to the co

Removing
– Turn cage to left to stop.
rrectness of i

– Press cage up and out of outer race.

l purpos

Installing
– Place cage in outer race.
nf
ercia

orm

– Installation position ⇒ page 168

m

atio
om

n in

– Secure cage by turning in direction of arrow to stop.

or c

thi
te

sd
iva

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rp

cu
o

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f

en
ng

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Cop py
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pyri by
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by
cted agen
Prote AG.

2. Dismantling and assembling freewheel with -B1- piston 167

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Installing rollers and springs

– Insert springs so that long end of spring -arrow- engages in
cage.
– Then insert rollers between cage and spring.

Location of cage in outer race

– Install with large lugs -arrow- facing up.

AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl

pt
du

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itte

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erm

Installation position of piston

ab
ility
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– Insert piston -A- as shown.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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f

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t.
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Cop py
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rig ht
py by
co Vo
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cted agen
Prote AG.

168 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3 Dismantling and assembling 1st to 3rd gear clutch -K1-

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
n AG. Volkswagen AG do
wage es n
♦ Thrust plate -VW 402- y Vo lks ot g
ua
b
ed ran
♦ Press tool -VW 412- horis tee
ut or
a ac
♦ Thrust piece -VW
ss 442-

ce
e
nl

pt
♦ Tube -40 - 203/1-
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Observe general repair instructions ⇒ page 11 .

The clutch may be dismantled only for cleaning or carrying out
visual check.
⇒ Clutches -K1- and -K3- may be pressed together in some gear‐
boxes.
Pressing -K1- off -K3- ⇒ page 124 .
Pressing -K1- onto -K3- ⇒ page 124 .

3. Dismantling and assembling 1st to 3rd gear clutch -K1- 169

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Support ring
❑ Unclip 4 pieces from in‐
ner plate carrier.
❑ Installing ⇒ page 171 .
2 - Inner plate carrier
❑ Installing ⇒ page 171 .
❑ Assembling
⇒ page 171 .
3 - Retaining ring
❑ Different thickness.
❑ Mark after removing and
insert at same point.
4 - Pressure plate
❑ Smooth side faces inner
plate.
❑ Insert together with in‐
ner plate carrier
⇒ page 171 .
5 - Inner plate
❑ Quantity ⇒ page 7 . AG. Volkswagen AG d
agen oes
❑ Installing ⇒ page 171 olksw not
y V gu
d b ara
❑ Lay in ⇒ ATF for 15 mi‐ orise nte
eo
nutes before installing auth
ra
ss c
6 - Outer plate

ce
e
nl

pt
du

an
❑ Quantity ⇒ page 7 .
itte

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erm

ab
❑ Installing ⇒ page 171

ility
ot p

❑ Always 1.5 mm thick

wit
, is n

7 - Outer plate h re
hole

spec
❑ Always 2.0 mm thick
es, in part or in w

t to the co

❑ Installing ⇒ page 171

8 - Corrugated washer
rrectness of i

9 - Retaining ring
l purpos

❑ Removing and installing ⇒ page 171

10 - Piston cap
nf
ercia

❑ Sealing lips are vulcanised to cap.

rm
m

atio

❑ Moisten sealing lips with ⇒ ATF before installing.

om

n in
c

❑ Turn cap slightly when installing.

or

thi
te

sd
iva

11 - Intermediate spring ring

o
r
rp

cu
o

❑ With spring support shell and compression springs.

f

en
ng

t.
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op
12 - Piston C py
t. rig
gh ht
❑ Using a screwdriver, carefully lever out of clutch housing at several points. yri
p by
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❑ Sealing lips are vulcanised to piston. cted agen
Prote AG.
❑ Moisten sealing lips with ⇒ ATF before installing.
❑ Turn piston slightly when installing.
13 - Clutch housing
❑ Before inserting inner plate carrier, place corrugated spring ⇒ Item 8 (page 170) and inner and outer
plates in clutch housing ⇒ page 171 .

170 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Removing and installing retaining ring

– Press piston cap with intermediate spring ring down far
enough for retaining ring -arrow- to be inserted in groove.

n AG. Volkswagen AG do
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Fitting pressure plate and plates onto inner plate carrier
ss

ce
le
un

pt
– Install pressure plate -a- with smooth side facing inner plate

an
d
itte
and stepped side towards inner plate carrier.

y li
erm

ab
ility
– Install 3 inner plates -b- and 2 outer plates -c- (1.5 mm).
ot p

wit
is n

– Clip in support ring with step -arrow-.

h re
ole,

spec
♦ Engage locating lugs correctly.
urposes, in part or in wh

t to the co
♦ Install corrugated washer and further plates in clutch housing
⇒ page 171 .

rrectnes
Installing corrugated washer and outer and inner plates in clutch

s o
cial p

housing

f inform
mer

– First insert corrugated washer.

atio
m

– Insert 2 mm thick outer plate.

o

n
c

i
or

n thi
e

– Insert remaining inner and outer plates (1.5 mm).

t

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

Inserting inner plate carrier and installing retaining ring -arrow-.

– Lift inner plate carrier slightly to install retaining ring.

3. Dismantling and assembling 1st to 3rd gear clutch -K1- 171

 Passat 1997 ➤ n AG. Volkswagen AG do
lkswage es n
4-speed automatic gearbox 01N - Edition 10.2005 d byV
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ua
ran
ir se tee
tho
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4 Dismantling and assembling reverse gear clutch -K2- ss

ce
le
un

pt
an
d
itte

y li
Special tools and workshop

erm

ab
ility
equipment required

ot p

wit
is n
♦ Thrust plate -VW 401-

h re
ole,

spec
♦ Removing tool -VW 460-

urposes, in part or in wh

t to the co
♦ Assembly ring -3267-

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Observe general repair instructions ⇒ page 11 .

The clutch may be dismantled only for cleaning or carrying out
visual check.
When doing, this ensure that the ball valve -arrow- is not dam‐
aged.

172 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Retaining ring
❑ Mark after removing and
insert at same point.
2 - Pressure plate
❑ Insert with smooth side
facing inner plates.
3 - Inner plate
❑ Quantity ⇒ page 7 .
4 - Outer plate
❑ Quantity ⇒ page 7 .
5 - Corrugated washer
6 - Retaining ring
❑ Removing and installing
⇒ page 173
❑ Installation position
⇒ page 174
7 - Spring support plate
❑ With springs.
❑ Installation position
⇒ page 174
8 - Spring support ring
9 - Piston gen AG
. Volkswagen AG
swa does
❑ Sealing lips y Volkare vulcan‐ not
gu
isedristo
e piston.
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❑ Moisten
auth
sealing lips with ra
s ⇒ ATF before installing.
s c
ce
e
nl

❑ Turn piston slightly

pt
du

an

when installing.
itte

y li
erm

ab

10 - Clutch housing
ility
ot p

wit

❑ With ball valve -arrow-.

, is n

h re
hole

spec
es, in part or in w

t to the co

Removing and installing retaining ring -arrow-

– Carefully press spring support plate down with assembly ring
-3267- just enough to be able to remove and install retaining
rrectness of i

ring.
l purpos

– Do not damage clutch housing ball valve.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

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o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Dismantling and assembling reverse gear clutch -K2- 173

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Installation position of spring support plate, checking retaining

ring
Retaining ring -arrow- must be seated in the groove of clutch
housing. Spring support plate must be centred relative to hub.
n AG. Volkswagen AG do
Do not confuse groove with shoulder on shaft. olkswage es n
ot g
yV ua
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s au ac
s

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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

174 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

5 Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine
shaft

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ -3292/1- from assembly
tool -3292-

n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Observe general repair instructions ⇒ page 11 .

rrectness of i

The clutch may be dismantled only for cleaning or carrying out

l purpos

visual check.
⇒ Clutches -K1- and -K3- may be pressed together in some gear‐
nform
ercia

boxes.
m

at
om

Pressing -K1- off -K3- ⇒ page 124 .

ion
c

in t
or

Pressing -K1- onto -K3- ⇒ page 124 .

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 175
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Retaining ring
❑ Different thickness.
❑ Mark after removing and
insert at same point.
2 - Pressure plate
❑ Install with stepped side
facing retaining ring.
3 - Inner plate
❑ Quantity ⇒ page 7 . n AG. Volkswagen AG do
lkswage es n
o ot g
yV
4 - Outer plate d b ua
ran
ir se tee
❑ Quantity ⇒ page 7 . autho
or
ac
ss
5 - Pressure plate

ce
le
un

pt
❑ Install with peened cor‐

an
d
itte

y li
rugated washer
rm

ab
⇒ Item 6 (page 176)
pe

ility
facing piston.
ot

wit
, is n

h re
6 - Corrugated washer
hole

spec
❑ Peened to pressure
es, in part or in w

t to the co
plate
⇒ Item 5 (page 176) .
7 - Retaining ring

rrectness of i
❑ Removing and installing
l purpos

⇒ page 177
8 - Piston cap

nform
ercia

❑ Sealing lips are vulcan‐

m

ised to piston cap.

a
com

tion in
❑ Moisten sealing lips with
r
te o

⇒ ATF before installing.

thi
s
iva

do
❑ Turn piston cap slightly
r
rp

cum

when installing.
fo

en
ng

t.
yi
❑ When removing and in‐
Co
op py
stalling, press down and
t. C rig
gh ht
yri
fit retaining ring ⇒ Item 7 (page 176) . p by
co Vo
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cted agen
9 - Spring Prote AG.

❑ Seat between piston and piston cap.

10 - Piston
❑ Sealing lips are vulcanised to piston.
❑ Moisten sealing lips with ⇒ ATF before installing.
❑ Turn piston slightly when installing.
11 - Clutch housing with turbine shaft
❑ There are two different versions ⇒ page 37 .
❑ Height varies according to number of inner and outer plates.
12 - O-ring
❑ Always renew
❑ Installing ⇒ page 177
13 - Piston ring
❑ Check for proper seating ⇒ page 177 .
❑ Removing and installing ⇒ page 177

176 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Removing and installing retaining ring -arrow-

– Press down carefully on piston cap until retaining ring can be
installed or removed.

Checking seating of piston rings

– Ensure that ends of piston rings are hooked together.

Removing and installing piston ring

Removing n AG. Volkswagen AG do
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– Compress piston ir se
d ring and release it.
b ua
ran
o tee
h
– Expand piston
s aut
ring on both sides and remove; do not twist out
or
ac
of groove on one side.
s
ce
e
nl

pt
du

Installing
an
itte

y li
erm

ab

– Place piston ring in groove.

ility
ot p

– To hook ends together, press sides of ring in and guide ends

wit
, is n

h re

over one another.

hole

spec
es, in part or in w

t to the co

Installing O-ring
– Insert O-ring in recess in turbine shaft -arrow-.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5. Dismantling and assembling 3rd and 4th gear clutch -K3- with turbine shaft 177
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

6 Removing and installing oil pan

Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306-

♦ Torque wrench -V.A.G 1331-

Removing
– Observe general repair instructions ⇒ page 11 . AG. Volkswagen AG d
agen oes
lksw not
– Remove noise insulation tray. byV
o gu
ara
ed
is nte
– Place drip tray -V.A.G 1306- underneath. ut
hor eo
a ra
s c
– Remove plug -3-. s
ce
e
nl

pt
du

– Remove overflow pipe -2- and allow ⇒ ATF to drain.

an
itte

y li
erm

ab

– Unscrew oil pan bolts -1- in diagonal sequence and remove

ility
ot p

oil pan.
wit
, is n

h re

Installing
hole

spec

Install in reverse order of removal. During this step, observe the

es, in part or in w

t to the co

following:
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

178 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Cut open seal -arrow- with side-cutting pliers; always renew

seal.
– Clean magnet in recess of pan. Ensure that magnet is seated
correctly in pan.
– Install oil pan with new gasket.

– Tighten pan bolts -1- diagonally in several stages

⇒ Item 4 (page 181) bolt.
– Install and bolt on overflow pipe -2- ⇒ Item 2 (page 181) .
– Screw in plug -3- hand-tight with new oil seal.
– Fill with 3 litres of ⇒ ATF, check ⇒ ATF level and top up
⇒ page 100 .

AG. Volkswagen AG d
agen oes
olksw not
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d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6. Removing and installing oil pan 179

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

7 Removing and installing ATF strainer

Removing
– Remove oil pan ⇒ page 178 .
– Pull ATF strainer off ⇒ valve body.
Installing

n AG. Volkswagen AG do
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– Push seal -1- oby
r hand onto intake neck -arrow- of ATF strainer.
ise
tee
th or
u
– Push ATFss strainer about 3 mm into ⇒ valve body (not to stop).
a ac
ce
e
nl

– When pan is installed, strainer will be pressed into correct in‐

pt
du

an
stallation position.
itte

y li
erm

ab

– Install oil pan ⇒ page 178 .

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

180 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8 Removing and
wage
installing
n AG. Volkswage⇒ valve
n AG doe body
ks s no
Vol t gu
d by ara
e
Cautionhoris nte
eo
ut ra
a c
ss
Do not run engine or tow vehicle with pan removed or when

ce
le
un

there is no ⇒ ATF in gearbox.

pt
an
d
itte

y li
erm

ab
ility
ot p

– Observe general repair instructions ⇒ page 11 .

wit
is n

h re
♦ The ⇒ valve body, the conductor strip and the adjacent parts
ole,

spec
can also be removed with the gearbox installed.
urposes, in part or in wh

t to the co
♦ After renewing ⇒ valve body or conductor strip, carry out basic
setting ⇒ page 45 .
♦ Dirty or defective ⇒ valve body.

rrectne
♦ Do not use fluffy cloths.

ss
♦ If renewing, refer to exchange component ⇒ page 17 .

o
cial p

f inform
– Then check ⇒ ATF level and top up ⇒ page 100 .
mer

atio
8.1 Assembly overview
om

n
c

i
or

n thi
Dismantling and assembling procedure ⇒ page 185
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1 - Plug
ng

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❑ Always renew seal
C py
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gh
⇒ page 183 .
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❑ Tightening ⇒ page 100
by lksw
cted agen
Prote AG.
2 - Overflow tube, 2 Nm
❑ Remove to drain ⇒ ATF
⇒ page 183 .
❑ Screw in to stop.
❑ Check ⇒ ATF level and
top up ⇒ page 100 .
3 - Oil pan
❑ Removing and installing
⇒ page 178
4 - Bolt, 12 Nm
❑ Loosen or tighten diag‐
onally and in steps
5 - Magnet
❑ Insert in recess in pan.
6 - Spacer bush
❑ Press into gasket.
7 - Seal
❑ Always renew
❑ Press spacer bushes
⇒ Item 6 (page 181) into
gasket.
8 - ATF strainer
❑ Removing and installing
⇒ page 180

8. Removing and installing valve body 181

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9 - Bolt, 5 Nm
❑ Qty. 13
❑ Observe tightening sequence ⇒ page 188 .
10 - Seal
❑ Always renew
❑ Push onto intake neck of strainer -arrow- by hand ⇒ page 185 .
11 - ⇒ Valve body
❑ Removing and installing ⇒ page 185
❑ Installation when using an exchange component ⇒ page 134 .
❑ Identification ⇒ page 183
❑ After installing a new ⇒ valve body, perform basic setting ⇒ page 45
12 - Bolt, 10 Nm
13 - Conductor strip with connector for ⇒ solenoid valves
❑ With cable bushing and connector.
❑ Can be removed and installed with gearbox installed.
❑ Removing and installing ⇒ page 190
❑ Gearbox oil temperature sender -G93- integrated in conductor strip.
❑ After installing a new conductor strip, perform basic setting ⇒ page 45
14 - O-ring
❑ For cable bushing.
❑ Always renew
15 - Plug wage
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❑ Cannot be removed from gearbox housing until after ⇒ valved bbody yV
o
has been removed. ot g
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❑ Take out before removing and installing freewheel. thoris tee
or
u
❑ Insert so that lug is located in groove on housing ⇒ page
ss
a
183 . ac

ce
e

❑ Put O-rings onto plug.

nl

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16 - O-ring
erm

ab
❑ Always renew

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❑ Moisten with ⇒ ATF and insert.

h re
hole

❑ Put O-ring onto plug ⇒ Item 15 (page 182) .

spec
es, in part or in w

17 - O-ring

t to the co
❑ Always renew
❑ Moisten with ⇒ ATF and insert.
❑ Put O-ring onto plug ⇒ Item 15 (page 182) . rrectness of i
l purpos

18 - Operating rod for spool valve

❑ Unhooking ⇒ page 185 .
nform
ercia

❑ Install in flattened side of spool valve ⇒ page 184 .

m

at
om

❑ Adjusting ⇒ page 185

ion
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❑ Always renew steel spring and bolt for spool valve control ⇒ page 184 .
o

his
ate

❑ Connecting operating rod and lever with steel spring and bolt ⇒ page 184 .
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182 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
AG. Volkswagen AG d
agen 4-speedoeautomatic gearbox 01N - Edition 10.2005
olksw s no
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Draining ⇒ ATF ris nte
utho eo
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a
– Place drip tray -V.A.G
ss 1306- underneath. c

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le
un

pt
– Remove plug -3-.

an
d
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– Remove overflow pipe -2- and allow ⇒ ATF to drain.
rm

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ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Replacing seal for plug
l purpos

– Cut open seal -arrow- with side-cutting pliers; always renew

seal.

nform
ercia

– After repairs, fit new seal to plug and screw in hand-tight when
m

a
filling with ⇒ ATF.
com

tion in
r

– Fill with ⇒ ATF; check ⇒ ATF level and top up ⇒ page 100 .
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Inserting plug
agen
Prote AG.

Pull plug out of housing before removing and installing freewheel

or plug and O-ring will be damaged.
– Coat new O-rings with ⇒ ATF and place on plug.
– Insert plug in hole in gearbox housing. Lug -arrow- engages
in oil channel.

Identification of ⇒ valve body

Code is stamped on a metal tab. The metal tab must remain at‐
tached to the ⇒ valve body.
Allocation of ⇒ valve body to gearbox ⇒ page 7

8. Removing and installing valve body 183

 Passat 1997 ➤ agen
AG. Volkswagen AG d
oes
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4-speed automatic gearbox 01N - Edition 10.2005
by Vol
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Always renew steel spring and bolt -arrow- au
th or
ac
ss
(For sake of clarity, selector shaft is shown removed.)

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– Remove steel spring -arrow- with operating rod and lever from

itte

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erm
selector shaft in gearbox.

ab
ility
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– To do this, unscrew bolt of steel spring from selector shaft and

wit
, is n
pull lever off selector shaft.

h re
hole

spec
♦ Always renew bolt with steel spring of spool valve.

es, in part or in w

t to the co
– If an exchange component is used, use new, supplied oper‐
ating lever.

rrectness of i
– Attach new steel spring and bolt on lever and operating rod
⇒ page 184 .
l purpos

Hooking operating rod into lever

nform
ercia

– Insert operating rod -1- from beneath into collar -arrow- of lever
m

-2-.

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Connecting operating rod and lever with steel spring and bolt
– Do not bend steel spring -2- when connecting to lever -4-.
– Hook new steel spring -2- with bolt -1- over end of operating
rod -3- -arrow A- and with retaining tab down, push over op‐
erating rod -arrow B-. At the same time, centre top of steel
spring on shoulder of lever -arrow a-.
– Swing steel spring over lever to stop.
– Tighten bolt until it is flush with lower edge of lever.

Hooking operating rod into spool valve

• ⇒ Valve body is bolted to gearbox housing.
• Spool valve is pulled slightly out of ⇒ valve body -arrow-.
– Move selector element and selector shaft to position “1”.
– Turn spool valve -1- so that flattened side -arrow- is to oper‐
ating rod -2-.
– Hook operating rod with lever into spool valve as shown.
– Only now place lever with new steel spring and loose bolt onto
selector shaft.
Do not bend operating rod -2-.
– Do not yet tighten bolt for lever.

184 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Adjusting operating rod for spool valve

– Move selector element and selector shaft to position “P”.
– Screw in bolt -2- for lever -1- into selector shaft by hand.
Do not yet tighten bolt so that it is still possible to make an ad‐
justment.
– Push operating rod -4- with spool valve -5- into ⇒ valve body
-3- to stop -in direction of arrow- and tighten bolt -2- for lever
to 4 Nm.
♦ Do not press on small limiting lever of steel spring or adjust‐
ment will be distorted.
♦ When tightened, spool valve must always contact stop in ⇒
valve body.
♦ Counterhold in direction of arrow when tightening bolt. Selec‐
tor lever must not be disturbed during tightening.
♦ Always replace bolt with retaining clip of spool
wage
valve.
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Installing seal utho eo
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a c
ss
– Push seal -1- by hand onto intake neck -arrow- of ATF strainer.

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erm

ab
ility
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spec
es, in part or in w

t to the co
rrectness of i
8.2 Dismantling and assembling procedure
l purpos

nf
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8. Removing and installing valve body 185

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required AG. Volkswagen AG d
agen oes
ksw
♦ Lever for conductor strip byV
ol not
gu
ara
-3373- rised
nte
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ut
♦ Torque wrench - ss a ra
c
V.A.G 1331-

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nl

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♦ Torque wrench -

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V.A.G 1783-

erm

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

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c

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for

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8.2.1 Removing
– Observe general repair instructions ⇒ page 11 .
– Remove oil pan ⇒ page 178 .
– Remove ATF strainer ⇒ page 180 .
– Remove conductor strip ⇒ page 190 .
Spool valve -1- remains in ⇒ valve body when ⇒ valve body is
removed.
– Move selector lever and selector shaft to position “1”.

186 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove steel spring -arrow- and lever with operating rod from
selector shaft in gearbox.
– To do this, unscrew bolt of steel spring from selector shaft and
pull lever off selector shaft.
(For sake of clarity, selector shaft is shown removed.)
♦ Always renew bolt with steel spring of spool valve.

Do not bend operating rod -2-.

– Pull spool valve out just until it is possible to unhook the op‐
erating rod -2-.
– Secure spool valve to prevent it from falling out.
– Do not interchange spool valves of valve bodies.
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– Remove only bolts marked with an arrow from ⇒ valve body.
rm

ab
pe

ility
– Do not loosen any other bolts. This would impair the function
ot

wit
, is n

of the ⇒ valve body.

h re
hole

– Detach ⇒ valve body carefully from gearbox.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

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t.
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– Pull freewheel plug -arrow- out of gearbox housing.
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by
cted agen
Prote AG.

8. Removing and installing valve body 187

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

8.2.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Coat 2 new O-rings with ⇒ ATF and place on plug.
– Insert plug in hole in gearbox housing. Lug -arrow- engages
in oil channel.

AG. Volkswagen AG d
agen oes
olksw not
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r
– Before securing ⇒ valve body to gearbox, pull spool
aut
ho
valve eo
ra
-1- out of ⇒ valve body as shown. ss c

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erm

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ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
– Set ⇒ valve body against gearbox and tighten bolts -arrows-
l purpos

hand-tight.
– Tighten bolts to specified torque, working from centre out‐

nform
ercia

wards ⇒ Item 9 (page 182) bolt.

m

at
om

i
– Move selector lever and selector shaft to position “1”.
on
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Prote AG.

188 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Turn spool valve -1- so that flattened side -arrow- is to oper‐

ating rod -2-.
– Hook operating rod with lever into spool valve as shown.
– Only now place lever with new steel spring and loose bolt
⇒ page 184 onto selector shaft.
– Adjust operating rod for spool valve ⇒ page 185 .
– Install conductor strip ⇒ page 190 .
– Install ATF strainer ⇒ page 180 .
– Install oil pan ⇒ page 178 .
After installation: perform basic setting ⇒ page 45

AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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an
d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
fo

en
ng

t.
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.

8. Removing and installing valve body 189

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

9 Removing and installing gearbox oil

temperature sender -G93-
Special tools and workshop equipment required
♦ Lever for conductor strip -3373-

♦ Torque wrench -V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
Removing auth eo
ra
ss c
– Observe general repair instructions ⇒ page 11 .
ce
e
nl

pt
du

an

– Remove oil pan ⇒ page 178 .

itte

y li
erm

ab

– Remove ATF strainer ⇒ page 180 .

ility
ot p

wit
, is n

– Remove bolt -1- in cable bushing.

h re
hole

spec

– Press connector for conductor strip out of gearbox housing

es, in part or in w

from outside inwards.

t to the co

– When removing conductor strip, do not damage gearbox oil

temperature sender -G93- -arrow 3-.
rrectness of i

– Do not kink or twist conductor strip.

l purpos

– Remove conductor strip using lever for conductor strip -3373- .

– Push -3373- under connectors for ⇒ solenoid valves to stop.
nform
ercia

– Lever off connector with -3373- in direction of arrow -2-.

m

at
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ion

Installing
c

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or

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ate

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for

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ng

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Prote AG.

190 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– When installing conductor strip, do not damage gearbox oil

temperature sender -G93- -arrow 3-.

– Route conductor strip as illustrated; when installing do not kink

or twist.
– Press connectors of conductor strip onto ⇒ solenoid valves
until they engage.
If fastener on ⇒ solenoid valves is damaged, ⇒ valve body must
be renewed.
– Put new seal on connector -1- and coat with ⇒ ATF.
– Insert connector -1- of conductor strip into gearbox housing
and tighten bolt -2- ⇒ Item 12 (page 182) bolt.
– Install ATF strainer ⇒ page 180 .
– Install oil pan ⇒ page 178 .
After installation: perform basic setting ⇒ page 45

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
ss c
ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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t.
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9. Removing and installing gearbox oil temperature sender G93 191

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

10 Dismantling and assembling ⇒ parking lock

Special tools and workshop

equipment required
♦ Multi-purpose tool -VW
771- n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Straightening tool -3114/2- ed by V ua
ran
ir s tee
♦ Torque wrench - autho
or
ac
V.A.G 1783- ss

ce
e
nl

pt
du

an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
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– Observe general repair instructions ⇒ page 11 .

192 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Bolt, 10 Nm
❑ Installing ⇒ page 195
2 - Lock washer
❑ Installing ⇒ page 195 .
3 - Bolt, 10 Nm
❑ Observe tightening se‐
quence ⇒ page 195 .
4 - Detent spring
❑ To remove, first remove
cover for pinion shaft
and output gear
⇒ page 212 .
❑ To remove, loosen bolts
⇒ Item 3 (page 193) and
⇒ Item 5 (page 193)
and raise locking lever
⇒ Item 10 (page 193)
for parking lock by hand.
❑ Observe tightening se‐
quence ob bolts during
installation
⇒ page 195 .
5 - Bolt, 10 Nm
❑ Observe tightening se‐
quence ⇒ page 195 .
6 - Engaging lever
❑ Insert together with se‐
lector shaft and detent
plate.
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7 - O-ring olksw not
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❑ Always renew rised
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❑ Insert with ⇒ ATF. s aut ra
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8 - Gearbox speed sender -G38-
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un

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d

❑ Can be checked using “guided fault finding” of -VAS 5051- .

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9 - Bolt, 10 Nm
pe

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10 - Detent lever
h re
hole

❑ To remove, first remove cover for pinion shaft and output gear ⇒ page 212 .
spec
es, in part or in w

❑ To remove, pull out to remove detent lever shaft ⇒ Item 12 (page 193) .
t to the co

❑ Insert with return spring.

11 - Parking lock gear
rrectness of i

❑ To remove, first remove cover for pinion shaft and output gear ⇒ page 212 .
l purpos

❑ Installation position: rounded-off side of parking lock gear faces pinion shaft cover.
❑ If renewed, shim “S4” for pinion shaft must be readjusted.
nform
ercia

12 - Shaft for detent lever

m

a
com

ti

❑ Pulling out ⇒ page 195

on in
r
te o

❑ Drive in with drift

thi
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❑ Peening ⇒ page 195 .

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13 - Return spring
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❑ Is supported by gearbox housing and is hooked into detent lever. C py
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Prote AG.

10. Dismantling and assembling parking lock 193

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

14 - Bolt, 10 Nm
15 - Retainer
❑ For multi-function switch.
16 - Multi-function switch -F125-
❑ Removing and installing ⇒ page 50
❑ Remove before removing selector shaft ⇒
AGItem
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en AG 194) .
agen does
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❑ Can be checked using “guided by Vfault finding” of -VAS 5051- . ot gu
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17 - O-ring oris tee
th or
au ac
❑ Always renew ss

ce
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❑ Insert with ⇒ ATF.

un

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itte

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18 - O-ring
erm

ab
ility
❑ Always renew
ot p

wit
is n

❑ Insert with ⇒ ATF.

h re
ole,

spec
19 - Driving speed sender -G68-
urposes, in part or in wh

❑ Can be checked using “guided fault finding” of -VAS 5051- .

t to the co
❑ Removing and installing ⇒ page 51
20 - Bolt, 10 Nm

rrectne
21 - Lever

ss
❑ For selector shaft

o
cial p

f in
22 - Bolt, 10 Nm

form
mer

atio
23 - Bearing bush
om

n
c

❑ Drive out and in with a drift.

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sd
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24 - O-ring
iv

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pr

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❑ Always renew
r
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t.
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❑ Insert with ⇒ ATF.
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❑ Insert in groove in selector shaft.
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25 - Selector shaft
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Prote AG.
❑ Before removing selector shaft, remove multi-function switch -F125- ⇒ Item 16 (page 194) and detent
spring ⇒ Item 4 (page 193) ⇒ page 195 .
❑ When installing, insert together with engaging lever ⇒ Item 6 (page 193) .
❑ Secure with washer ⇒ Item 2 (page 193) ⇒ page 195 .
26 - Spool valve actuator
❑ Removing ⇒ page 185 .
❑ Always renew steel spring and bolt for spool valve control ⇒ page 184 .
❑ Assembling ⇒ page 184 .
❑ Adjusting ⇒ page 185
27 - Bolt, 5 Nm
❑ Always renew ⇒ page 184 .

194 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Pulling out shaft for detent lever

– Pull out shaft with multi-purpose tool -VW 771- .

Peening shaft for detent lever

– Drive in shaft with threaded hole upwards.
– Apply punch -A- to gearbox housing and secure shaft by pe‐
AG. Volkswagen AG d
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h re
Removing and installing selector shaft
hole

spec
– Remove bolt -arrow- and remove lock washer.
es, in part or in w

t to the co

♦ The lock washer must be inserted in groove of selector shaft

and secures the selector shaft from working its way out.
rrectness of i

♦ After detent spring -A- is removed, selector shaft can be re‐

moved or installed.
l purpos

nform
mercia

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tion in
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Starting bolts for detent spring

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– Screw in bolts -1- and -2- about 3 full turns.

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ng

t.
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– Tighten bolt -2- ⇒ Item 3 (page 193) bolt, and then tighten bolt
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-1- ⇒ Item 5 (page 193) bolt.
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Prote AG.

10. Dismantling and assembling parking lock 195

 Passat 1997 ➤
4-speed automatic gearbox
agen
01N
AG. Vo-lkEdition
swagen A10.2005
G do
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olks ot g
yV ua
Removing and installingris
ebreather
d b
for ⇒ planetary gearbox or final
ran
tee
drive. tho or
au ac
ss
1 - Breather cap

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pt
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2 - Breather

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3 - Breather pipe

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- Remove with pliers.
, is n

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hole

- Drive onto stop with copper drift.

spec
es, in part or in w

t to the co
rrectness of i
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196 Rep. Gr.38 - Gears, control

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

11 Renewing speedometer sender -

G22- or driving speed sender -G68-
Additional required information
♦ Workshop manual Passat 1997 ▸ Running gear, axles, steer‐
ing front and four-wheel drive
Removing
– Remove left wheel.
Vehicles with TDI engine
n AG. Volkswagen AG do
wage e n
– Remove left drive yV
oshaft noise insulation from swheel
lks ot g housing
ua
-arrows-. ised b ran
or tee
h
Continuationau for all vehicles
t or
ac
ss

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nl

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es, in part or in w

t to the co
– Pull connector -arrow A- off sender.
rrectness of i
– Press down retaining clip on sender and rotate -arrow-.
l purpos

– Pull out sender.

nform

Installing
mercia

Install in reverse order of removal. During this step, observe the

at
om

io

following:
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c

in t
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– Replace O-rings -arrows-. rig ht
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– Insert new O-rings with gear oil. cted agen
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– Insert sender.
– Engage retaining clip on bearing bracket for flange shaft.
– Install left wheel ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 44 ; Installing wheels and tyres:
Installing wheel .

11. Renewing speedometer sender G22 or driving speed sender G68 197
 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

39 – Final drive - differential

1 Checking gear oil in final drive
Special tools and workshop equipment required
AG. Volkswagen AG d
♦ Torque wrench -V.A.G 1331- agen oes
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aut ra
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ab
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Drive vehicle a short distance to warm up gear oil.

rrectne
– Position vehicle over pit or on 4-pillar hoist so that it stands
level.

ss o
cial p

f
Vehicles with TDI engine

inform
mer

– Remove left drive shaft noise insulation from wheel housing

atio
-arrows-.
om

n
c

i
or

n
Continuation for all vehicles

thi
te

sd
va

– Place drip tray -V.A.G 1306- underneath.

i

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pr

cum
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fo

en
Checking:
ng

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Oil level is checked with gearbox installed.
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– Remove inspection plug -arrow- for gear oil and top up to lower
edge of hole with gear oil.
The oil level is correct when the front final drive is filled to the lower
edge of the filler hole.
– Allow excess gear oil to run out or top up as necessary.
Specification ⇒ page 10
– Clean magnet on plug.
– Install plug.
Torque setting ⇒ Item 10 (page 220)
Vehicles with TDI engine

198 Rep. Gr.39 - Final drive - differential

 AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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horis
eo Passat 1997 ➤
ut
ss a 4-speed automatic
ra
c gearbox 01N - Edition 10.2005

ce
le
un

pt
– Install noise insulation for left drive shaft in wheel housing

an
d
itte
-arrows-.

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

1. Checking gear oil in final drive 199

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

2 Renewing oil seal for left or right

flange shaft

2.1 Renewing oil seal for left flange shaft

(Gearbox installed)

Special tools and workshop

equipment required
♦ Extractor tool -VW 681-
♦ Thrust piece -3377-
♦ Torque wrench -V.A.G
1331-

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pe

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es, in part or in w

t to the co
rrectness of i
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a
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tion in
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te o

thi
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cted
Additional required information
agen
Prote AG.

♦ Workshop manual Passat ▸ Running gear, axles, steering

front and four-wheel drive

2.1.1 Removing
Wheel bearing must not be loaded when hexagon bolt is loose.
If the wheel bearing is loaded with the weight of the vehicle, the
wheel bearing will sustain initial damage. This will shorten the
service life of the wheel bearing.
If a vehicle must be moved after the drive shaft has been re‐
moved, first install an outer joint in place of the drive shaft and
tighten to 50 Nm or the wheel bearing will be damaged.

200 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Remove hexagon bolt for drive shaft. (Loosen only with vehicle
standing on its wheels - danger of accident.)
– Remove wheel.
Vehicles with TDI engine
– Remove left drive shaft noise insulation from wheel housing
-arrows-.
Continuation for all vehicles
– Remove drive shaft ⇒ Running gear, axles, steering front and
four-wheel drive; Rep. Gr. 40 ; Servicing drive shaft; Remov‐
ing and installing drive shaft .
– Place drip tray -V.A.G 1306- underneath.
– Remove tapered bolt for drive shaft using -V.A.G 1669- or
commercially available 6 mm socket. en AG. V
olkswagen AG
ag does
ol ksw not
To do this, screw two bolts into flange shaft and counterhold
yV gu
db ara
flange shaft with an assembly lever. rise nte
ho eo
ut
– Pull out flange shaft with compression spring.
ss
a ra
c

ce
e

– Pull out flange shaft oil seal using oil seal extractor -VW 681- .
nl

pt
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itte

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ab
2.1.2 Installing

ility
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– Moisten outer circumference of seal with gear oil.

h re
hole

spec
– Drive in new seal to stop, being careful not to cant seal.
es, in part or in w

t to the co
– Half-fill space between sealing lip and dust lip with grease -
G 052 128 A1- .
– Install flange shaft with compression spring, support ring, ta‐

rrectness of i
pered ring and retaining ring.
l purpos

The thrust chamfer of the taper ring faces differential.

nf
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– The two lugs -2- on drive gear of speedometer sender must

rp

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engage between the tabs -1- of the support ring.

f

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t.
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op
– Install drive shaft ⇒ Running gear, axles, steering front and
C py
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gh
four-wheel drive; Rep. Gr. 40 ; Repairing drive shaft; Remov‐
ht
pyri by
Vo
ing and installing drive shaft .
co lksw
by
cted agen
Prote AG.
Vehicles with TDI engine

2. Renewing oil seal for left or right flange shaft 201

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install noise insulation for left drive shaft in wheel housing

-arrows-.
Continuation for all vehicles
– Install wheel ⇒ Running gear, axles, steering - front and four-
wheel drive; Rep. Gr. 44 ; Installing wheels and tyres: Instal‐
ling wheel .
– Tighten tapered bolt for drive shaft using -V.A.G 1669- or com‐
mercially available 6 mm socket ⇒ Item 1 (page 220) .
– With gearbox installed, check gear oil level in final drive
⇒ page 198 .

2.2 Renewing right drive flange oil seal

(Gearbox installed)
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agen oes
Special tools and workshop Volksw not
gu
equipment required d by ara
ise nte
or eo
h
♦ Extractor tool -VW 681- s aut ra
c
s
♦ Thrust piece -3236-

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un

pt
an
d
itte

♦ Fitting tool -3244-

y li
erm

ab
ility
♦ Thrust piece -3323-
ot p

wit
is n

♦ -2- Puller -Kukko 18/1-

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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or

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Prote AG.

2.2.1 Removing
Wheel bearing must not be loaded when hexagon bolt is loose.
If the wheel bearing is loaded with the weight of the vehicle, the
wheel bearing will sustain initial damage. This will shorten the
service life of the wheel bearing.

202 Rep. Gr.39 - Final drive - differential

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Passat 1997 ➤
ris
ut
ho 4-speed e o automatic
ra
gearbox 01N - Edition 10.2005
s a c
s
If a vehicle must be moved after the drive shaft has been re‐

ce
le
un

pt
moved, first install an outer joint in place of the drive shaft and

an
d
itte

y li
tighten to 50 Nm or the wheel bearing will be damaged.
rm

ab
pe

ility
– Remove hexagon bolt for drive shaft. (Loosen only with vehicle
ot

wit
standing on its wheels - danger of accident.)
, is n

h re
hole

– Remove wheel.

spec
es, in part or in w

Vehicles with TDI engine

t to the co
– Remove right drive shaft noise insulation from wheel housing
-arrows-.

rrectness of i
Continuation for all vehicles
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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op py
– Remove left drive shaft guard plate -arrows-. The third bolt is
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ht ht
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not visible in the figure. py by
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– Remove right drive shaft -1- ⇒ Running gear, axles, steering
Prote AG.
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Remove cap by piercing cap centre with a screwdriver and
levering out.
– Place drip tray -V.A.G 1306- underneath.
– Remove securing ring for drive flange.

– Pull off drive flange.

A - Puller , e.g. -Kukko 18/1-
– Pull out flange shaft oil seal using oil seal extractor -VW 681- .

2.2.2 Installing
– Moisten outer circumference of seal with gear oil.

2. Renewing oil seal for left or right flange shaft 203

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Drive in new seal to stop, being careful not to cant seal.

– Half-fill space between sealing lip and dust lip with grease -
G 052 128 A1- .

– Pull drive flange in.

– Install a new retaining ring and new cap.

– Install right drive shaft -1- ⇒ Running gear, axles, steering -

front and four-wheel drive; Rep. Gr. 40 ; Repairing driveswa
gen AG
. Volkswagen AG
does
shafts; Removing and installing drive shafts . by Volk not
gu
d ara
se nte
– Install right drive shaft guard plate -arrows-.thoThird
ri bolt cannot e or
be seen in figure ⇒ Running gear, axles,s asteering
u - front and ac
four-wheel drive; Rep. Gr. 40 ; Repairing s
drive shafts; Re‐
ce
e
nl

moving and installing drive shafts .

pt
du

an
itte

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Vehicles with TDI engine
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Install noise insulation for right drive shaft in wheel housing

-arrows-.
rrectness of i

Continuation for all vehicles

l purpos

– Install wheel ⇒ Running gear, axles, steering - front and four-

wheel drive; Rep. Gr. 44 ; Installing wheels and tyres: Instal‐
ling wheel .
nform
ercia

– With gearbox installed, check gear oil level in final drive

m

at

⇒ page 198 .
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2.3 Removing and installing deep groove ball bearing for output shaft of drive
Co
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Prote AG.

204 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required
♦ Fitting sleeve -3378-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Grip -V.A.G 1582/10-

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ility
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hole

spec
es, in part or in w

Removing

t to the co
• Differential is installed.
– Remove right drive flange oil seal ⇒ page 202 .
rrectness of i
– Lever out retaining ring for deep groove ball bearing.
l purpos

– Insert hexagon bolt M 12 x 20 with washer in hole of output

shaft for drive flange.
nform
ercia

– Tighten claws of adapter -V.A.G 1582/10- between balls on

m

a
com

inner race of deep groove ball bearing.

ion in
r
te o

– Pull out deep groove ball bearing with tapered roller bearing
thi
s
iva

puller -V.A.G 1582- .

do
r
rp

cum
fo

Installing
en
ng

t.
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Cop py
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by
cted agen
Prote AG.

2. Renewing oil seal for left or right flange shaft 205

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Pull in deep groove ball bearing together with tapered ring and
compression spring.
– Insert retaining ring for deep groove ball bearing.
– Drive in right drive flange oil seal ⇒ page 202 .
AG. Volkswagen AG d
agen oes
olksw not
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ce
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

206 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3 Dismantling and assembling final

drive

3.1 Overview - final drive repair

Refer to table on ⇒ page 229 to avoid unnecessary adjustment
work following repairs to final drive.
AG. Volkswagen AG d
agen oes
olksw not
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by
1 - Input gear rised ara
nte
o eo
❑ Removing and installing aut
h
ra
⇒ page 208 ss c

ce
le
un
❑ Adjusting ⇒ page 230

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❑ Adjusting final drive
erm

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(overview)

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⇒ page 229 .

wit
is n

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❑ Repairs on the input
ole,

gear can only be per‐

spec
urposes, in part or in wh

formed after the individ‐

t to the co
ual components of the ⇒
planetary gearbox have
been removed.

rrectne
2 - Pinion shaft
❑ Removing and installing

ss
⇒ page 212

o
cial p

f in
❑ Adjusting pinion shaft

form
mer

and crown wheel

atio
⇒ page 233 .
om

n
c

i
❑ Adjusting final drive
or

n thi
e

(overview)
t

sd
va

⇒ page 229 .
i

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pr

cum
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fo

en
ng

3 - Differential
t.
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op
❑ Removing and installing
C py
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⇒ page 219
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❑ Dismantling and assem‐ Prote
cted AG.
agen
bling ⇒ page 222
❑ Adjusting pinion shaft
and crown wheel
⇒ page 233 .
❑ Adjusting final drive
(overview)
⇒ page 229 .

3. Dismantling and assembling final drive 207

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3.2 Removing and installing input gear

Special tools and workshop

equipment required
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Multi-purpose tool -VW
771-
♦ Thrust plate -30 - 205-
♦ Drift sleeve -40 - 21-
♦ Thrust plate -40 - 105-

AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
rrectness of i
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or c

thi
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by lksw
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Prote AG.

208 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
. Volkswagen AG
gen AG does
Special tools and workshop
Vol
ksw
a
not
equipment required
ed
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ara
is nte
or
♦ Drift sleeve
au -40 - 20-
th eo
ra
ss c
♦ Press tool -40 - 503-

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nl

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♦ Torque wrench -V.A.G
itte

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1576-
erm

ab
ility
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♦ Tapered roller bearing pull‐

wit
, is n

er -V.A.G 1582-

h re
hole

spec
♦ Grip -V.A.G 1582/3-
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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– Observe general repair instructions ⇒ page 11 .

2) Adjustment work is required if these components are replaced ⇒ Adjustment
overview ⇒ page 229 .

3. Dismantling and assembling final drive 209

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Clamping bolt, 250 Nm

❑ To remove or install, en‐
gage ⇒ parking lock.
❑ Removing and installing
⇒ page 211
❑ Before installing clamp‐
ing bolt, insert needle
thrust bearing
⇒ Item 7 (page 210) .
2 - Dished spring
❑ Convex side faces
clamping bolt.
3 - Shim
❑ Determining thickness
⇒ Adjusting input gear
⇒ page 230 .
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4 - Tapered roller bearing inner Volkswa not
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race 2) db
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❑ Remove together uwith tho eo
ra
input gear ss a c
⇒ Item 10 (page 210) .

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❑ After measuring shim,
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place it on input gear
erm

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with locking fluid -AMV

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185 101 A1- .

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❑ To install, drive a few
hole

spec
millimetres onto input
es, in part or in w

gear t to the co
⇒ Item 10 (page 210)
and then pull in with
clamping bolt
rrectness of i

⇒ Item 1 (page 210) .

l purpos

5 - Tapered roller bearing outer

race 2)
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❑ Drive out using drift

orm

❑ Drive in with thrust plate -30 - 205- .

m

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❑ Insert with locking fluid -AMV 185 101 A1-

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or c

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6 - Gearbox housing 2)
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7 - Needle thrust bearing

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❑ Install with flat side facing input gear.
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❑ Insert into input gear before installing clamping bolt ⇒ Item 1 (page 210) .
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8 - Tapered roller bearing outer race 2)
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❑ Drive out with drift.
❑ Drive in with thrust plate -30 - 205- and appropriately long drift.
❑ Insert with locking fluid -AMV 185 101 A1-
9 - Tapered roller bearing inner race 2)
❑ Pulling off ⇒ page 211
❑ Pressing on ⇒ page 211
❑ Insert with locking fluid -AMV 185 101 A1-
10 - Input gear 2)
❑ With impulse wheel for driving speed sender -G68- .
❑ Removing ⇒ page 211 .
❑ Number of teeth ⇒ page 7 .
❑ Adjusting ⇒ page 230

210 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
❑ If input gear or output gear are damaged, always renew together.
❑ If input gear is renewed, adjust planet carrier ⇒ page 146 .
11 - Cover
❑ Driving out ⇒ page 212
❑ Driving in ⇒ page 212

Pulling off tapered roller bearing inner race

– Place thrust plate -40 - 105- on input gear.

Pressing on tapered roller bearing inner race

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gen AG d
A thrust piece must be placed under
Vol
kswthe hub of the input gear
a oes
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avoid damage to the input gear.
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ac
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es, in part or in w

t to the co

Removing input gear

– Place press tool -40 - 503- with collar in threaded hole of input
rrectness of i

gear.
l purpos

– Connect press tool to multi-purpose tool -VW 771- through in‐

put gear hole.
nform
ercia

– Carefully drive out input gear.

m

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Removing and installing clamping bolt
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A - Torque wrench
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B - Deep socket insert, 22 mm ⇒ AF cted agen
Prote AG.

– To loosen or tighten engage ⇒ parking lock.

3. Dismantling and assembling final drive 211

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Driving out cover

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3.3 Removing and installing pinion shaft

rrectne
Refer to table on ⇒ page 229 to avoid unnecessary adjustment

s
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s o
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Prote AG.

212 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Special tools and workshop

equipment required
♦ Drift -VW 295-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 412-
♦ Thrust piece -VW 433-
♦ Removal and installing tool
-VW 459/2-

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3. Dismantling and assembling final drive 213

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Threaded spindle -VW 517-

♦ Thrust plate -30 - 11-
♦ Thrust plate -30 - 205-
AG. Volkswagen AG d
♦ Drift sleeve -40 - 20- lksw
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Prote AG.

214 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Thrust pad -3062-

♦ Assembly sleeve -3187-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Grip -V.A.G 1582/6-
♦ -1- Two arm puller -Kukko
20/10-

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3) Adjustment work is required if these components are renewed ⇒ Adjustment

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overview ⇒ page 229 . t. Cop py
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3. Dismantling and assembling final drive 215

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Pinion shaft 3) wage

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❑ To remove, remove dif‐ d byV
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❑ Paired with crown s au ac
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❑ Number of teeth

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⇒ page 7 .

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❑ Adjusting pinion shaft

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and crown wheel

spec
⇒ page 233 .
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❑ Installing ⇒ page 217 .
2 - Tapered roller bearing inner

rrectness of i
race 3)
❑ Pulling off ⇒ page 217
l purpos

❑ Pressing on
⇒ page 218

nform
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3 - Sleeve for pinion shaft 3)

m

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❑ Pull off together with ta‐

on
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pered roller bearing in‐
or

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agen
-3138- .
❑ Pulling in ⇒ page 218
5 - Shim “S3”
❑ Determining thickness
⇒ page 237 , Adjusting
pinion shaft.
6 - Cover
❑ Driving out ⇒ page 219
❑ Driving in ⇒ page 219
7 - Hexagon nut
❑ Always renew
❑ Engage ⇒ parking lock to remove or install.
❑ Torque specification ⇒ page 237 , Adjusting pinion shaft.
❑ Peening ⇒ page 219 .
8 - Tapered roller bearing inner race 3)
9 - Tapered roller bearing outer race 3)
❑ Drive out using drift
❑ Pressing in ⇒ page 219 .
10 - Bolt, 25 Nm
❑ Insert with sealant -AMV 188 200 03- .
❑ Tighten diagonally and alternately.
11 - Cover 3)
❑ For pinion shaft
12 - O-ring
❑ Always renew

216 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
Volkswa
❑ Can be renewed swith
wagegearbox installed.does
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13 - Spacer tubesed3)by ara
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❑ Installation
aut
ho position: wider contact surface faces output e o gear.
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14 - Shim “S4”

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e
nl

pt
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❑ Determining thickness ⇒ page 237 , Adjusting pinion shaft.
itte

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15 - Output gear 3)

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❑ Pulling off ⇒ page 218
hole

spec
❑ Install hot.
es, in part or in w

t to the co
❑ If input gear or output gear is damaged, always renew together.
❑ Installation position: the higher collar faces parking lock gear.

rrectness of i
16 - Parking lock gear 3)
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❑ Rounded side faces output gear.

17 - Seal for pinion shaft

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❑ Drive out using drift

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❑ Always renew
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❑ Do not grease or oil sealing lips.

or

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To avoid damage to sealing lips, the assembly sleeve -3187- isProte AG.
used to insert the pinion shaft.

Pulling off tapered roller bearing inner race with sleeve for pinion
shaft

3. Dismantling and assembling final drive 217

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Pressing on tapered roller bearing inner race with sleeve for pin‐
ion shaft

Pulling tapered roller bearing outer race into gearbox housing

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Driving in pinion shaft seal to stop
Insert seal but do not grease or oil sealing lips.

rrectness of i
Installation position of seal:
l purpos

Higher inner collar faces parking lock gear.

– Drive in seal onto stop.

nform
mercia

at
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Prote AG.

218 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Pressing in tapered roller bearing outer race

Locking hexagon nut

– Using a punch, peen collar of hexagon nut against flattened
side of pinion shaft -arrows-.

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Driving in cover
cial p

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– Drive new cover in to stop with thrust sleeve -40 - 20- .

mer

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3.4 Removing and installing differential

Refer to table on ⇒ page 229 to avoid unnecessary adjustment
work following repairs to final drive.
– Observe general repair instructions ⇒ page 11 .
4) Adjustment work is required if these components are replaced ⇒ Adjustment
overview ⇒ page 229 .

3. Dismantling and assembling final drive 219

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Countersunk bolt, 30 Nm
2 - Flange shaft
❑ Removing and installing
⇒ page 200
3 - Compression spring for
flange shaft
4 - Thrust washer
❑ Installation position:
shoulder faces spring,
lugs face tapered ring
5 - Tapered ring
❑ With grooves to engage
in thrust washer
❑ Installation position:
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
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❑ Remove with oil seal ex‐ thor eo
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❑ Before installing, half-fill

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-G 052 128 A1- .
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hole

⇒ page 200 .

spec
es, in part or in w

❑ Driving in ⇒ page 201

t to the co
8 - Speedometer drive wheel
❑ For speedometer sender -G22- .

rrectness of i
❑ Remove and install after removing flange shaft seal.
l purpos

❑ Installation position: lugs along inner circumference face flange shaft and taper faces differential.
9 - Hexagon bolt, 25 Nm
nform
ercia

❑ Insert with sealant -AMV 188 200 03- .

m

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❑ Tighten diagonally and alternately.

on in
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te o

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10 - Oil filler plug, 25 Nm

s
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ng

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11 - Speedometer sender -G22-
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12 - O-ring
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❑ Always renew
13 - Final drive cover 4)
❑ If renewed, adjust crown wheel ⇒ page 233 .
14 - O-ring
❑ Always renew
❑ Can be renewed with gearbox installed.

220 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

15 - Differential 4)
❑ Dismantling and assembling ⇒ page 222
❑ To remove, first remove differential cover and right drive flange.
❑ If renewed, adjust pinion shaft and crown wheel ⇒ Adjustment overview ⇒ page 229 .
❑ To install, tapered ring must be removed.
16 - Bolt, 10 Nm
❑ Insert with sealant -AMV 188 200 03- .
17 - Cover
❑ For axle breathing.
18 - Seal
❑ Always renew
19 - Compression spring
❑ With differential installed, pull in together with deep groove ball bearing
AG. Volk⇒
swItem 21 (page 221) and tapered
agen A
ring ⇒ Item 20 (page 221) ⇒ page 206 . swagen G do
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20 - Tapered ring ris
ed ran
tee
ho
❑ Installation position: stepped collar faces reverseaut gear. or
ac
ss
❑ With differential installed, pull in together with deep groove ball bearing and compression spring

ce
le
un

⇒ page 206 .

pt
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rm

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❑ Removing and installing ⇒ page 204
ot

wit
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❑ Remove before removing differential.

h re
hole

spec
22 - Retaining ring
es, in part or in w

t to the co
❑ Lever out with a screwdriver
23 - Sealing cap

rrectness of i
❑ To remove, pierce sealing cap with screw driver.
❑ Drive in with 30 mm ⇒ AF socket.
l purpos

❑ Always renew

nform
ercia

24 - Retaining ring
m

a
25 - Drive flange
com

tion in
❑ Removing and installing ⇒ page 202
r
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thi
s
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26 - Drive flange oil seal

do
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❑ Before installing, half-fill space between sealing lips with sealing grease -G 052 128 A1- .
fo

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t.
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❑ Can be renewed with gearbox installed ⇒ page 200 .
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❑ Remove with oil seal extractor lever -VW 681- .
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❑ Driving in ⇒ page 204
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3. Dismantling and assembling final drive 221

 AG. Volkswagen AG d
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Passat 1997 ➤ oris nte
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th
4-speed automatic gearbox 01N - Edition
s au 10.2005 ra
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s

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3.5 Assembly overview - dismantling and assembling differential

an
d
itte

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Special tools and workshop

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equipment required

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spec
♦ Thrust plate -VW 402-

es, in part or in w

t to the co
♦ Press tool -VW 412-
♦ Thrust piece -VW 454-

rrectness of i
♦ Removal and installing tool l purpos
-VW 459/2-
♦ Tube -VW 519-

nform
ercia

♦ Thrust plate -30 - 205-

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Prote AG.

222 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Drift sleeve -40 - 21-

♦ Fitting tool -3046-
♦ Tapered roller bearing pull‐
er -V.A.G 1582-
♦ Grip -V.A.G 1582/3-

AG. Volkswagen AG d
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5) Adjustment work is required if these components are renewed ⇒ Adjustment

spec

overview ⇒ page 229 .

es, in part or in w

t to the co
rrectness of i
l purpos

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Prote AG.

3. Dismantling and assembling final drive 223

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

1 - Sun wheel
❑ Removing and installing
⇒ page 227
2 - Threaded piece
❑ When assembling, in‐
sert lugs in sun wheel.
❑ Insert before installing
planet pinion pin.
3 - Planet pinion
❑ Removing and installing
⇒ page 227
4 - Planet pinion
❑ Removing and installing wage
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⇒ page 227 yV
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5 - Retaining ring ir se tee
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❑ For output shaft ss
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6 - Sun wheel

pt
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❑ Removing and installing
erm

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⇒ page 227

ility
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wit
7 - One-piece thrust washer
, is n

h re
hole

❑ Insert with gear oil.

spec
es, in part or in w

8 - Shim “S1”

t to the co
❑ Determining thickness
⇒ Adjusting crown

rrectness of i
wheel ⇒ page 242 .
l purpos

9 - Tapered roller bearing outer

race 5)
❑ Remove with drift

nform
ercia

-3138- .
m

at
❑ Pressing in
om

ion

⇒ page 225 .
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te

10 - Tapered roller bearing inner race 5)

a

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❑ Pulling off ⇒ page 225

um
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t.
❑ Pressing on ⇒ page 226
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11 - Ribbed bolt
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❑ Tighten to 80 Nm and turn 60° further.
c by lksw
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❑ Always renew
12 - Differential pinion pin
❑ Removing and installing ⇒ page 227
13 - Differential cage 5)
14 - Crown wheel 5)
❑ Number of teeth ⇒ page 7 .
❑ Install hot ⇒ page 226 .
❑ Paired with pinion shaft. Renew only as a set.
❑ Drive off differential cage with drift.
❑ Allocation according to gearbox code letters ⇒ Electronic parts catalogue “ETKA” .
15 - Tapered roller bearing inner race 5)
❑ Pulling off ⇒ page 225
❑ Pressing on ⇒ page 226

224 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

16 - Tapered roller bearing outer race 5)

❑ Drive out using drift
❑ Pulling in ⇒ page 226
17 - Shim “S2”
❑ Determining thickness ⇒ Adjusting crown wheel ⇒ page 242 .
18 - Output shaft for drive flange
❑ Removing and installing ⇒ page 227

Pressing in tapered roller bearing outer race

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Pulling off tapered roller bearing inner race

nl

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– Place thrust piece -40 - 105- on differential cage.
erm

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t to the co
rrectness of i
l purpos

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c

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for

en
ng

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Cop py
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gh ht
pyri by
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by
cted agen
Prote AG.

3. Dismantling and assembling final drive 225

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Pressing on tapered roller bearing inner race

WARNING

Wear protective gloves!

– Heat inner race to about 100 °C.

♦ The temperature can be checked with thermometer -
V.A.G 1558- .
. Volkswage
– Press on tapered rollerwabearing
gen AG inner race tooestop
n AG d
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tial cage. Volks t gu
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Install crown wheel hot.

h re
hole

spec
es, in part or in w

WARNING
t to the co
Wear protective gloves! rrectness of i
l purpos

– Heat crown wheel to about 100 °C.

♦ The temperature can be checked with thermometer -
nform
ercia

V.A.G 1558- .
m

– Push crown wheel over centring pins -A- (locally manufac‐

com

tio

tured) onto differential housing.

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iva

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Pulling tapered roller bearing outer race into gearbox housing

r
rp

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I - Insert tapered roller bearing outer race into gearbox housing

en
ng

t.
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using thrust plate -30 - 205- .
Co
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II - Screw thrust piece from fitting tool -3046- to spindle and use
rig by
opy Vo
it to pull in outer race. by c lksw
cted agen
Prote AG.

226 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

3.6 Dismantling and assembling differential

(procedure)

3.6.1 Dismantling
– Remove bolts on crown wheel and drive off differential cage
using drift.
– Drive out planet pinion pin -4- for planet pinion gears -3-.
– Remove threaded piece.
– Remove 3 gears from differential cage.

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– Remove retaining ring -A- from output flange for drive flange
ot p

-arrow-.

wit
, is n

h re
hole

– Remove 4th gear and output shaft.

spec
es, in part or in w

– Remove one-piece thrust washer.

t to the co
rrectness of i
l purpos

nform
mercia

at
om

io
3.6.2 Assembling
n
c

in t
or

his
te

– Insert one-piece thrust washer ⇒ Item 7 (page 224) with gear

a

do
riv

oil in differential cage -1-.

p

cum
for

en
ng

– Insert output shaft -2- in differential housing -1-.

t.
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Cop py
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– Observe installation position: the side with two bearing seats yri
gh by
ht
-arrows- faces differential.
op Vo
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– Set sun wheel on output shaft and secure to shaft with retain‐
AG.

ing ring.

3. Dismantling and assembling final drive 227

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert flange shaft -1- as assembly aid in differential housing

-2-.
– Secure sun wheel to flange shaft with bolt and threaded piece.
– Insert planet pinions offset 180° and swing in by turning flange
shaft.

– Carefully drive in planet pinion pin -A- so that one-piece thrust

washer is not damaged.
– Install crown wheel hot ⇒ page 226 .
– Remove flange shaft from differential cage.

AG. Volkswagen AG d
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erm

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ility
ot p

wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

228 Rep. Gr.39 - Final drive - differential

 AG. Volkswagen AG d
agen
Volksw
oes
not Passat 1997 ➤
by gu
ised 4-speed
ara
nte automatic gearbox 01N - Edition 10.2005
or eo
th
s au ra
c
s
4 Adjusting final drive

ce
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un

pt
an
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Refer to table on ⇒ page 229 to avoid unnecessary adjustment

y li
rm

ab
work following repairs to final drive.
pe

ility
ot

wit
4.1 Overview of adjustments
, is n

h re
hole

spec
es, in part or in w

1 - Shim “S1” for crown wheel

t to the co
2 - Tapered roller bearings for
differential

rrectness of i
3 - Shim “S2” for crown wheel
l purpos

4 - Pinion shaft

nform
ercia

❑ Adjusting pinion shaft

and crown wheel
m

a
⇒ page 233 .
com

tion in
r
te o

5 - Shim “S3” for pinion shaft

thi
s
iva

do
r

6 - Large tapered roller bearing

rp

cum
fo

for pinion shaft

en
ng

t.
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op
7 - Input gear C py
t. rig
gh ht
yri
❑ Adjusting ⇒ page 230 p by
o Vo
by c lksw
cted agen
8 - Tapered roller bearing for Prote AG.
input gear
9 - Shim for input gear
10 - Small tapered roller bear‐
ing for pinion shaft
11 - Shim “S4” for pinion shaft
12 - Output gear
13 - Crown wheel
❑ Adjusting pinion shaft
and crown wheel
⇒ page 233 .
14 - Tapered roller bearings for
differential

4.2 Adjustments to be completed after renewing individual components

♦ Following repairs to the gearbox, it is necessary to readjust the
input gear, pinion shaft with output gear or crown wheel with
differential cage only if components have been renewed which
directly affect the final drive adjustment. To prevent unneces‐
sary adjustments, refer to the following table:
To be adjusted:
Components being replaced: Crown wheel Crown wheel Pinion shaft Pinion shaft Adjusting in‐
“S1”+“S2” “S1” “S3” + “S4” “S4” put gear 6)
⇒ page 233 ⇒ page 233 ⇒ page 233 ⇒ page 233 ⇒ page 230
Gearbox housing X X X
Tapered roller bearing for in‐ X
put gear

4. Adjusting final drive 229

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Always renew input gear X X

and output gear together
Always renew pinion shaft X X
and crown wheel together
Differential cage without X
crown wheel
Tapered roller bearing for pin‐ X
ion shaft . Volkswagen AG
gen AG does
swa
Tapered roller bearings for X yV
olk not
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differential ised b ara
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or eo
Final drive cover aut
h
X ra
ss c
Cover for pinion shaft, sleeve X

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for pinion shaft, parking lock

pt
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d
itte

gear, spacer tube

y li
rm

ab
pe

ility
6) If input gear is adjusted, also adjust planet carrier and play between K1 and K2.
ot

wit
, is n

h re
hole

spec
4.3 Adjusting input gear
es, in part or in w

t to the co
Special tools and workshop equipment required
♦ Measurement bridge -VW 382/7-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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thi
s
iva

do
r
rp

cum
fo

en
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t.
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Cop py
ht. rig
rig ht
py by
o Vo
♦ Torque wrench -V.A.G 1576- by c lksw
cted agen
Prote AG.

♦ Dial gauge
Procedure
– Insert outer races for both tapered roller bearings and inner
race for inner tapered roller bearing using locking fluid -AMV
185 101 A1- ⇒ Item 5 (page 210) and ⇒ Item 8 (page 210) .
– Insert input gear with inner race of inner tapered roller bearing
in gearbox housing.

230 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Tighten clamping bolt to 100 Nm without dished washer and

without shim.
A - Torque wrench
B - 22 mm socket
The ⇒ parking lock must be engaged.
– Remove clamping bolt.

– Insert dial gauge and set to “0” with 3 mm preload.

– Measure distance between input gear -B- and tapered roller
bearing inner race -A-.
– Note measured value (example 1.00 mm).
The thickness of the dished washer ,1.50 mm, must be added
to the reading of 1.00 mm, result = 2.50 mm.
Determining thickness of shim
The specified bearing preload geis
n Aachieved
G. Volkswagifenthe
AG bearing preload
of 0.18 mm is subtracted ol swa the figure obtaineddofrom
kfrom es n
ot the meas‐
V gu
urement (dished washer
sed by
+ reading) of 2.50 mm. ara
n ri tee
ho
Example: aut or
ac
ss
ce
e

Dished washer + reading 2.50 mm

nl

pt
du

an

- Bearing preload 0.18 mm

itte

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erm

ab

= Thickness of shim 2.32 mm

ility
ot p

wit
, is n

– Determine shim from table.

h re
hole

spec

Table of shims for input gear

es, in part or in w

t to the co

Measured thick‐ Shim to be fit‐ Measured thick‐ Shim to be fit‐ Measured thick‐ Shim to be fit‐
ness (mm) ted (mm) ness (mm) ted (mm) ness (mm) ted (mm)
rrectness of i

1.575 … 1.599 1.600 1.900 … 1.924 1.925 2.225 … 2.249 2.250

l purpos

1.600 … 1.624 1.625 1.925 … 1.949 1.950 2.250 … 2.274 2.275

1.625 … 1.649 1.650 1.950 … 1.974 1.975 2.275 … 2.299 2.300
nform
ercia

1.650 … 1.674 1.675 1.975 … 1.999 2.000 2.300 … 2.324 2.325

m

at

1.675 … 1.699 1.700 2.000 … 2.024 2.025 2.325 … 2.349 2.350

om

ion
c

1.700 … 1.724 1.725 2.025 … 2.049 2.050 2.350 … 2.374 2.375

in t
or

his
e

1.725 … 1.749 1.750 2.050 … 2.074 2.075 2.375 … 2.399 2.400

at

do
priv

1.750 … 1.774 1.775 2.075 … 2.099 2.100 2.400 … 2.424 2.425

um
for

en
g

1.775 … 1.799 1.800 2.100 … 2.124 2.125 2.425 … 2.449 2.450

n

t.
yi Co
op py
1.800 … 1.824 1.825 2.125 … 2.149 2.150 2.450 … 2.474 2.475
. C rig
ht ht
rig by
py
1.825 … 1.849 1.850 2.150 … 2.174 2.175 2.475 … 2.499 2.500
co Vo
by lksw
cted agen
1.850 … 1.874 Prote
1.875 2.175 … 2.199 2.200 2.500 … 2.524 2.525
AG.

1.875 … 1.899 1.900 2.200 … 2.224 2.225 2.525 … 2.549 2.550

Various tolerances make it possible to obtain the exact shim
thickness required.
Part number ⇒ Electronic parts catalogue “ETKA”

– Remove input gear again ⇒ page 208 .

4. Adjusting final drive 231

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert inner race for outer tapered roller bearing with locking
fluid -AMV 185 101 A1- .
– Insert needle thrust bearing for input shaft.
– Fit shim onto input gear.
– Location of bearing ⇒ Removing and installing input gear
⇒ page 208 .
– Tighten clamping bolt and dished spring
⇒ Item 1 (page 210) .
Installation position of dished spring:
Small diameter faces clamping bolt.

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wit
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

232 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

5 Adjusting pinion shaft and crown

wheel

5.1 General notes

Careful adjustment of the crown wheel and pinion shaft is essen‐
tial to ensure that the final drive gives long service and Aruns
G. Volkswagen AG d
agen
silently. Therefore, the crown wheel and pinionVoshaft lksw are matched
oes
not
gu
during production and checked on testing machines ed by to ensure that ara
nte
the mesh pattern is correct and the gears thorisrun quietly. The position eo
for quietest running is obtained by movingau the pinion shaft axially ra
c
ss
while maintaining the backlash within the specified tolerances.

ce
le
un

pt
The allowance “r” based on the master gauge “Ro” is marked on

an
d
itte

y li
outer circumference of the crown wheel. Renew gear set (crown
rm

ab
wheel and pinion shaft) together only!
pe

ility
ot

wit
, is n

5.2 Adjustment and marking of final drive gear sets

h re
hole

spec
es, in part or in w

t to the co
1 - Identification “1143” indi‐
cates Oerlikon gear set with a
ratio of 43:11.

rrectness of i
2 - Pair number “312” of final
l purpos

drive gear set

3 - Allowance “r” is based on

nform
ercia

the test machine master gauge

used in the production. The al‐
m

a
lowance “r” is always given in
com

tio
1/100 mm. Example: “26” indi‐

n in
r
te o

cates r = 0.26 mm.

thi
s
iva

do
Ro - Length of test machine
r
rp

cum
fo

master gauge used. “Ro” = en

ng

t.
59.20 mm
yi Co
Cop py
t. rig
R - Actual distance between
gh ht
yri by
crown wheel axis and face of cop Vo
by lksw
cted
pinion shaft in position of qui‐
agen
Prote AG.
etest running for this gear set.

5. Adjusting pinion shaft and crown wheel 233

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Vo - Hypoid offset

5.3 Recommended sequence for new ad‐

justment of final drive gear set
When crown wheel and pinion shaft have to be adjusted, in the
interests of an efficient procedure, keep to the following order:
1 - Total shim thickness “Stotal” (Determine “S1” + “S2”) for pre‐
loading of tapered roller bearings for differential ⇒ page 242 .
2 - Adjust preload of tapered roller bearings for pinion shaft
⇒ page 237 .
3 - Determine thickness of shims “S3” and “S4” ⇒ page 241 .
4 - Adjust backlash. Select shims “S1” and “S2” so that the speci‐
fied backlash between pinion shaft and crown wheel is obtained
⇒ page 244 .
. Volkswagen AG
a gen AG does
The purpose of this adjustment is to reestablish the position Vol of‐
ksw not
gu
fering the quietest running as calculated on the test machine
ed by ara
nte
during production. The utmost care and cleanliness thoduring all as‐
ris eo
sembly work and measurements are essential to auachieve a good ra
c
ss
result.

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pt
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Special tools and workshop
rm

ab
pe

equipment required

ility
ot

wit
, is n

♦ Gear set removal lever -VW

h re
hole

296-

spec
es, in part or in w

♦ Universal test gauge -

t to the co
VW 385/1-
♦ Centring disc -VW 385/2-

rrectness of i
♦ Measuring rod -VW 385/14-
l purpos

♦ Dial gauge extension -

VW 385/16-

nform
ercia

♦ End dimension plate -

m

a
VW 385/17-
com

tion in

♦ Universal master gauge -

r
te o

thi

VW 385/30-
s
iva

do
r
rp

♦ End dimension plate -

um
fo

en
g

VW 385/33-
n

t.
yi Co
Cop py
♦ Universal dial gauge brack‐
t. rig
gh ht
yri
et -VW 387- p by
o Vo
by c lksw
cted agen
♦ Adjustable measuring lever Prote AG.
-VW 388-
♦ Thrust plate -VW 402-
♦ Press tool -VW 407-

234 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Press tool -VW 412-

♦ Thrust piece -VW 433-
♦ Thrust piece -VW 454-
♦ Removal and installing tool
-VW 459/2-
♦ Threaded spindle -VW 517-
♦ Setting gauge -VW 521/4-
AG. Volkswagen AG d
♦ Setting gauge -VWlk521/8-
swa
gen oes
not
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yV gu
edb ara
ris nte
tho eo
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c
ss

ce
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un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5. Adjusting pinion shaft and crown wheel 235

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ Thrust plate -30 - 205-

♦ Support bridge -2011-
♦ Tube -2040-
♦ Fitting tool -3046-
♦ Thrust pad -3062-
♦ Assembly sleeve -3187-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c

ce
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un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
♦ Torque wrench -V.A.G 1601-
agen
Prote AG.

236 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

♦ -3- Splitter -Kukko 17/2-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
♦ Deep socket insert, 41 mm ⇒ AF
hole

spec
es, in part or in w

♦ Dial gauge

t to the co
5.4 Adjusting pinion shaft

rrectness of i
It is necessary to readjust the pinion shaft when the following
components are renewed:
l purpos

♦ Gearbox housing

nform
ercia

♦ Tapered roller bearing for pinion shaft

m

at
♦ or final drive gear set
om

ion
c

in t
r

If the pinion shaft sleeve, parking lock gear, input or output gear,
o

his
e

spacer sleeve or pinion shaft cover is renewed, only shim “S4”

at

do
riv

must be redetermined.
p

cum
for

en
ng

Adjustment overview ⇒ page 229

t.
yi Co
Cop py
t. rig
Determining total shim thickness “Stotal” for shims “S3” + “S4” opyri
gh by
Vo
ht
c by lksw
(Setting preload of tapered roller bearings for pinion shaft). cted agen
Prote AG.

– Press on tapered roller bearing inner race with sleeve for pin‐
ion shaft.

– Press large tapered roller bearing outer race with 1.50 mm

thick temporary shim “S3” into bearing plate to stop.
As a test prerequisite, a shim “S3” of 1.5 mm must be temporarily
installed. It is referred to below as “S3*”. After value “e” is deter‐
mined, “S3*” is replaced with final shim “S3”.

5. Adjusting pinion shaft and crown wheel 237

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Press tapered roller bearing outer race into cover for pinion
shaft.

– Insert pinion shaft in gearbox housing.

A - Assembly sleeve -3187-
To avoid damage to sealing lips, the assembly sleeve -3187- is
used to insert the pinion shaft.

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lkswage es n
o ot g
byV ua
d ran
ir se tee
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– Press pinion shaft against outer race of tapered roller bearing
ce
le
un

in gearbox housing using transmission removal lever -VW

pt
an
d
itte

296- .
y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

– Fit parking lock gear, heated output gear and a 2.40 mm thick
o
cial p

f i

shim in place of “S4” -arrow- (2 shims, each 1.20 mm thick).

nform
mer

– Push on spacer tube.

atio
om

n
c

Installation position of parking lock gear, output gear and spacer

i
or

n thi
e

tube ⇒ page 212 .

t

sd
iva

o
pr

– Fit cover for pinion shaft.

um
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

238 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Insert inner race for tapered roller bearing and screw hexagon
nut -arrow- onto pinion shaft.
– Tighten 4 bolts for pinion shaft cover to 25 Nm.
– Engage ⇒ parking lock.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Initially tighten new hexagon nut to 350 Nm.

ility
ot p

A - Torque wrench

wit
, is n

h re
hole

B - 41 mm socket

spec
es, in part or in w

– Loosen hexagon nut and tighten to 240 Nm.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
– Attach dial gauge and set to “0” with 1 mm preload.
om

n in
c

– Move pinion shaft up and down and note dial gauge reading
or

thi
e

(example: 0.95 mm).

t

sd
iva

o
r
rp

cu

Do not turn the pinion shaft whilst measuring or the bearings will
o

m
f

en
ng

settle and a false reading will be obtained.

t.
yi Co
op py
The specified bearing preload is achieved if the reading
t. C rig
gh ht
yri
(0.95 mm), the preload of the bearings (0.15 mm) and the amount p by
co Vo
for settling (0.10 mm) are deducted from the 2 x 1.2 mm thick
by lksw
cted agen
Prote
shims.
AG.

Determining thickness of temporary shim “S4*”

After measured value “e” is determined, temporary shim S“S4*”
is replaced with final shim “S4”.
Example:
Fitted shim ( in place of “S4”) 2.40 mm
- Measured value 0.95 mm
- Preload 0.15 mm
- Amount for settling 0.10 mm
= Thickness of shim “S4*” 1.20 mm

– Remove pinion shaft cover, spacer pipe and 2.40 mm shim.

– Determine shim “S4*” according to table ⇒ page 231 and set
on pinion shaft.

5. Adjusting pinion shaft and crown wheel 239

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Install pinion shaft cover.

– Initially tighten hexagon nut to 350 Nm, loosen, tighten to
240 Nm and peen with punch -arrow-.
Determining dimension “e”
Dimension “e” is required to determine the final thickness
n AG. Volkof
swashims
gen AG
“S3” and “S4”. lkswage does
not
Vo g by ua
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Adjust setting ring of universal test gauge -VW 385/1- to di‐

ility
ot p

mension -a- = 70 mm.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

– Assemble universal test gauge as shown in figure.

ion
c

in t
or

A - Dial gauge extension -VW 385/16- = 12.3 mm long

his
ate

do
riv

– Set universal gauge -VW 385/30- to Ro = 59.2 mm.

p

cum
for

en
ng

t.
– Set dial gauge (3 mm range) to zero with 2 mm preload.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place end measuring plate on face of pinion shaft.

– Insert universal test gauge -A-.
– Fit final drive cover and tighten 4 bolts.
– Use sliding setting ring to pull 2nd centring disc outwards until
test gauge can still just be turned by hand.
Determining dimension “e”

240 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Turn test gauge until point of dial gauge makes contact with
end measuring plate and indicates max. deflection (return
point). The measured value is dimension “e”.
Example: 0.32 mm (black range). AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove universal test gauge. ed b ara
nte
ris
ho eo
Finally, check again whether dial gauge returns
aut to “0” with 2 mm ra
c
preload with master gauge -VW 385/30- applied.
ss
Otherwise re‐

ce
le
peat measurement.

un

pt
an
d
itte

y li
Determining thickness of shim “S3”

erm

ab
ility
♦ If measurement is obtained on red scale, add value “e”. ot p

wit
is n

h re
♦ If measurement is obtained on black scale, subtract value “e”.
ole,

spec
urposes, in part or in wh

♦ The allowance “r”, based on the master gauge “Ro” is meas‐

t to the co
ured for the pinion shaft sets supplied as replacement parts
and marked on the outer circumference of the crown wheel.
“S3” = “S3*” + e - r

rrectne
(“e” in red scale)

ss o
Example:
cial p

f inform
Already installed shim 1.50 mm
mer

atio
Value indicated on dial gauge “e” +0.32 mm
om

n
c

i
Dimension “r” -0.26 mm
or

n thi
te

sd
a

Shim thickness “S3” = 1.56 mm

iv

o
pr

cum
r
fo

en
ng

– Ascertain thickness of shim according to table ⇒ page 241

t.
yi Co
and determine part No. according to ⇒ parts catalogue “ET‐ . Cop py
KA” .
ht rig
rig ht
py by
co Vo
Determining thickness of shim “S4”
by lksw
cted agen
Prote AG.

Example:
Already installed shim 1.20 mm
Value indicated on dial gauge “e” +0.32 mm
Dimension “r” -0.26 mm
Shim thickness “S4” = 1.26 mm

– Ascertain thickness of shim according to table ⇒ page 242

and determine part No. according to ⇒ parts catalogue “ET‐
KA” .
If a thicker shim “S3” is required, a thicker shim “S4” (same dif‐
ference) must be installed.
If a thinner shim “S3” is required, a thinner shim “S4” (same dif‐
ference) must be installed.

Shim table “S3”

Shim thickness in mm
1.05 1.30 1.55 1.80
1.10 1.35 1.60 1.85
1.15 1.40 1.65
1.20 1.45 1.70
1.25 1.50 1.75

5. Adjusting pinion shaft and crown wheel 241

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005
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Shim table “S4” byV
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Shim 7) thickness in mm auth or
ac
ss
1.000 1.225 1.450 1.675 1.900

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1.025 1.250 1.475 1.700 1.925

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1.050 1.275 1.500 1.725 1.950

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1.075 1.300 1.525 1.750 1.975

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1.100 1.325 1.550 1.775 2.000
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1.125 1.350 1.575 1.800 2.400
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t to the co
1.150 1.375 1.600 1.825
1.175 1.400 1.625 1.850

rrectness of i
1.200 1.425 1.650 1.875
l purpos

7) The various thicknesses of shim “S4” make it possible to find the exact shim thickness required. Insert two shims if necessary.

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Carry out check measurement - checking dimension “r”
m

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n in
– Install pinion shaft with measured shims “S3” and “S4” and
or c

thi
rotate several times in each direction.
te

sd
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– Insert universal test gauge and measure dimension “r”.

rp

cu
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m
f

en
ng

t.
If the correct shims have been selected, the dial gauge, read anti-
yi Co
op
clockwise on the red scale, must now indicate the given deviation
C py
t. rig
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“r” within a tolerance of 0.04 mm.
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5.5 Adjusting crown wheel

(Adjusting differential)
It is necessary to readjust the crown wheel when the following
components are renewed:
♦ Gearbox housing
♦ Final drive cover
♦ Tapered roller bearings of differential
♦ Differential cage
♦ or final drive gear set
Adjustment overview ⇒ page 229
Determining total shim thickness “Stotal” for shims “S1” + “S2”
(Adjusting preload on differential tapered roller bearings)
• Pinion shaft and differential are removed.
– Remove shims ⇒ Item 8 (page 224) .
– Insert 1.5 mm shim (2 shims each 0.75 mm) in seat for outer
race of tapered roller bearing (“S2” side).

242 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Drive tapered roller bearing outer race with shim “S2” into
gearbox housing.
As a test prerequisite, a shim “S2” of 1.5 mm must be temporarily
installed. It is referred to below as “S2*”. After value “e” is deter‐
mined, “S2*” is replaced with final shim “S2”.

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es, in part or in w

– Press outer race for tapered roller bearing without shim into

t to the co
cover for differential.
– Insert differential in gearbox housing.

rrectness of i
– Set cover in place and tighten bolts ⇒ Item 9 (page 220) .
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5. Adjusting pinion shaft and crown wheel 243

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– Attach dial gauge and set to “0” with 1 mm preload.

When performing measurement, do not turn differential or the
bearings will settle and the result of the measurement will be fal‐
sified.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.60 mm)
Stotal = “S2*” + measurement + preload
Example:
Fitted shim(s) “S2*” 1.50 mm
Measured value (example) +0.60 mm
Preload (constant value) +0.40 mm
Total shim thickness “Stotal” = 2.50 mm

Determining thickness of shim “S1*”

♦ After backlash is determined, temporary shim “S1*” is re‐
placed with final shim “S1”.
♦ The total shim thickness “Stotal” remains unchanged.
“S1*” = Stotal - “S2*”
Example:
Volkswagen AG
Total shim thickness “Stotal”swagen AG. does 2.50 mm
k not
Vol g
Fitted shim(s) “S2*” sed by -1.50uamm
ran
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Thickness of shim aut “S1*” = 1.00 mm or a
ss c
ce
e

Allocate shims according to ⇒ Electronic parts catalogue “ETKA” .

nl

pt
du

an
itte

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erm

ab

– Press outer race for tapered roller bearing with determined

ility
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shim “S1*” (in example 1,00 mm) into differential cover.

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h re

– Set cover in place and tighten bolts ⇒ Item 9 (page 220) .

hole

spec

Adjusting backlash
es, in part or in w

t to the co

Pinion shaft installed with “S3” and “S4”

– Compensation: “Stotal” (“S1” + “S2”) installed in gearbox
rrectness of i

housing.
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– Fit final drive cover and tighten bolts to 25 Nm.

– Turn differential several times in both directions so that ta‐
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ercia

pered roller bearings settle.

rm
m

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c

– Set up measuring tools.

or

thi
te

sd

– Set adjustable measuring lever -VW 388- to dimension “a” =

iva

o
r

70 mm.
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m
f

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ng

t.
– Turn crown wheel until it makes contact with a tooth flank (end op
yi Co
of backlash travel).
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yri by
– Set dial gauge to zero with 1 mm preload.
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– Turn back crown wheel to stop on opposite tooth flank and
read backlash. Note reading.

244 Rep. Gr.39 - Final drive - differential

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

– If pinion shaft turns when differential is turned, fit splitter -A-

(e.g. Kukko 17/2) so that backlash can be measured exactly.
– Loosen locking screw of clamping sleeve and after turning
crown wheel a further 90°, repeat complete measuring proc‐
ess 3 more times. Add the four results and calculate the
average backlash.
Calculating average backlash
Example:
1st measurement 0.49 mm
+ 2nd measurement 0.48 mm
+ 3rd measurement agen 0.50 mm AG does
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+ 4th measurement d by
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Total thor
1.96 mm eo
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c
ss
Average backlash: 1.96 mm / 4 = 0.49 mm.

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le
un

pt
an
If the individual measurements differ among each other by more
d
itte

y li
than 0.06 mm, either the crown wheel is improperly installed or
erm

ab
the crown wheel and pinion themselves are defective. Recheck

ility
ot p

installation and if necessary renew crown wheel and pinion.

wit
is n

h re
ole,

Determining shim thickness “S2”

spec
urposes, in part or in wh

– Multiply backlash by 1.17 (constant value) and subtract prod‐

t to the co
uct from thickness of already installed shim “S2” and add result
to 0.20, (constant value for lift).

rrectne
(opposite crown wheel)

s
“S2*” = Inserted shim(s)

s o
cial p

f
- Average backlash

inform
mer

+ Lift (constant value)

atio
om

Lift = 0.20 mm n
c

i
or

n thi
e

Example:
t

sd
iva

o
pr

cum
r

“S2*” = fitted shim(s) 1.50 mm

fo

en
ng

t.
yi Co
- Average backlash Cop 0.57 mm py
0.49 mm x 1.17
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+ Lift (constant value) 0.20 mm
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Thickness of shim “S2” 1.13 mm
AG.

– Determine shim from table ⇒ page 246 .

Determining shim thickness “S1”
(crown wheel side)
“S1” = Stotal - “S2”
Example:
Total shim thickness “Stotal” 2.50 mm
Thickness of shim “S2” -1.13 mm
Thickness of shim “S1” = 1.37 mm

5. Adjusting pinion shaft and crown wheel 245

 Passat 1997 ➤
4-speed automatic gearbox 01N - Edition 10.2005

Table of shims “S1” and “S2”

Shim thickness (mm)

0.55 0.75 0.95
0.60 0.80 1.00
0.65 0.85 1.05
0.70 0.90
Allocate shims according to parts catalogue.
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure.
– Various tolerances make it possible to obtain the exact shim
thickness required.
– Install determined shims “S1” and “S2”.

Carrying out control measurement - measuring backlash

– After installing shims “S1” and “S2”, turn differential 5 turns in
both directions so that tapered roller bearings settle.
– Measure backlash four times on circumference.
– It must be 0.15...00.25 mm.

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es, in part or in w

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Prote AG.

246 Rep. Gr.39 - Final drive - differential