Gearbox 001 PDF

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

S00.5318.00.20
The Workshop Manual is intended only for use within the Organisation koda.
It is not permitted to pass it on to other persons.
KODA AUTO a. s.
Service
Printed in Czech Republic

S00.5318.00.20
FABIA 2000 Automatic Gearbox 001
List of Supplements to Workshop Manual
FABIA 2000
Edition 07.00
Suppleme
nt
Subject
Article Number
07.00
Basic Edition
S00.5318.00.20
12.02
Supplement to Basic Edition
S00.5318.01.20
04.05
Supplement to Rep. - Gr. 00, 01, 37, 38, 39
S00.5318.02.20
Edition 04.05
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Edition
List of Supplements
List of Supplements
Edition 04.05
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Table of Contents
00 Technical Data
Technical Data for the Gearbox ..................................................................... 00-1
page
- Identification of the gearbox ......................................................................... 00-1
page
- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1
page
- Capacity ................................................................................................. 00-1
page
Information and repair Instructions for the Automatic Gearbox 001 ....................... 00-2
page
- Information on the Automatic Gearbox 001 ....................................................... 00-2
page
- Repair instructions .................................................................................... 00-2
page
- Explanation of the terms used in this workshop manual. ........................................ 00-2
page
Function of Self-diagnosis ........................................................................... 01-1
page
- Function of Self-diagnosis ............................................................................ 01-1
page
- Self-diagnosis technical data ........................................................................ 01-1
page
...................................... 01-2
page
- Vehicle components .................................................................................. 01-2
page
- Electric/electronic components of the gearbox ................................................... 01-2
page
Performing self-diagnosis ............................................................................ 01-3
page
- Test conditions ......................................................................................... 01-3
page
- Work sequence ........................................................................................ 01-3
page
- Overview of selectable functions .................................................................... 01-3
page
- Interrogating and erasing fault memory ............................................................ 01-3
page
Fault Table and Initiating Basic Setting .......................................................... 01-4
page
- Fault table .............................................................................................. 01-4
page
- Initiating basic setting ................................................................................. 01-4
page
Reading measured value block ..................................................................... 01-5
page
- List of display groups ................................................................................. 01-5
page
- Test table ............................................................................................... 01-5
page
Inspecting the solenoid valves and shift elements while driving ........................... 01-6
page
- Solenoid valves and position of the shift elements ............................................... 01-6
page
Electrical Test ........................................................................................... 01-7
page
- Test procedure ......................................................................................... 01-7
page
- Check the wiring between the automatic gearbox control unit -J217- and the gearbox .... 01-7
page
Torque Converter ....................................................................................... 32-1
page
- Identification of the torque converter ............................................................... 32-1
page
- Draining the torque converter ........................................................................ 32-1
page
- Removing and installing gasket ring for torque converter ....................................... 32-1
page
- Installing the torque converter ....................................................................... 32-1
page
Checking shifting points ............................................................................. 37-1
page
Measure limit speed of the hydraulic converter ................................................. 37-2
page
Fault finding ............................................................................................. 37-3
page
01 Self-diagnosis, Electrical Test
Electric/Electronic Components and Fitting Locations
32 Torque Converter
37 Control, housing
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- Before fault finding .................................................................................... 37-3
- Safety measures ...................................................................................... 37-3
page
page
1
1
- Fault finding table ..................................................................................... 37-3
page
Inspecting gearshift mechanism ................................................................... 37-4
page
- Inspecting gearshift mechanism .................................................................... 37-4
page
- Inspecting and adjusting the selector lever control cable ....................................... 37-4
page
Removing and Installing Shift Mechanism ...................................................... 37-5
page
- Removing and Installing Shift Mechanism ........................................................ 37-5
page
- Removing and installing the selector lever control cable ........................................ 37-5
page
- Removing and installing the selector lever grip ................................................... 37-5
page
Disassembling and assembling the gearshift mechanism ................................... 37-6
page
- Adjusting latch spring with roller .................................................................... 37-6
page
- Removing and installing selector lever lock solenoid -N110- ................................... 37-6
page
Removing and installing the gearbox ............................................................. 37-7
page
- Removing ............................................................................................... 37-7
page
- Installing ................................................................................................ 37-7
page
Checking and topping up ATF level ............................................................... 37-8
page
- Inspecting ATF level .................................................................................. 37-8
page
- Topping up ATF ....................................................................................... 37-8
page
- Replacing ATF ......................................................................................... 37-8
page
Disassembling and assembling the gearbox .................................................... 37-9
page
- Gearbox with shift elements ......................................................................... 37-9
page
- Removing and installing ATF radiator and ATF filler tube ...................................... 37-9
page
Disassembling and assembling planetary gear - Summary of components ............. 37-10 page
- I - Removing and installing ATF pump up to large sun gear ................................... 37-10 page
- II - Removing and installing cover for gearbox housing up to the drive gear ................ 37-10 page
Disassembling and assembling planetary gear - Assembly sequence .................... 37-11 page
- Disassembling planetary gear ....................................................................... 37-11 page
- Assembling planetary gear .......................................................................... 37-11 page
Adjusting work on planetary gear .................................................................. 37-12 page
- Overview ............................................................................................... 37-12 page
- Adjusting reverse gear-brake -B1- ................................................................. 37-12 page
............................................................ 37-12 page
- Setting clutch clearance .............................................................................. 37-12 page
- 2. Adjust 2nd and 4th gear-brake -B2-
38 Wheels, Control
II
Disassembling and assembling the ATF pump ................................................. 38-1
page
Disassembling and assembling overrunning clutch ........................................... 38-2
page
1. Disassembling and assembling 1st through 3rd gear clutch -K1- ....................... 38-3
page
Disassembling and assembling the reverse gear-clutch -K2- ............................... 38-4
page
Disassembling and assembling 3rd and 4th gear-clutch -K3- ............................... 38-5
page
Disassembling and assembling the reverse gear-brake -B1- ................................ 38-6
page
Disassembling and assembling the piston for 2nd and 4th gear-brake -B2- ............. 38-7
page
Removing and installing slide valve body - Summary of components .................... 38-8
page
- Removing and installing ATF strainer .............................................................. 38-8
page
- Solenoid valve -N93- .................................................................................. 38-8
page
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- Removing and installing retaining plate with solenoid valves -N88- through -N92- ......... 38-8
page
Disassembling and assembling the parking position ......................................... 38-9
page
Replacing flange shaft gasket rings ............................................................... 39-1
page
Disassembling and assembling the final drive .................................................. 39-2
page
- Repair overview of the final drive ................................................................... 39-2
page
- Disassembling and assembling the input shaft ................................................... 39-2
page
- Disassembling and assembling the differential ................................................... 39-2
page
............................................................................. 39-3
page
- Overview of adjusting works ......................................................................... 39-3
page
- Adjusting works when replacing individual components ........................................ 39-3
page
- Adjusting the differential gear ........................................................................ 39-3
page
- Adjusting the input shaft .............................................................................. 39-3
page
39 Final drive, differential
Adjusting the final drive
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IV
Table of Contents
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00
00 Technical Data
00-1
Technical Data for the

Gearbox
Identification of the gearbox

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

Identification characters and manufacturing data of
the gearbox -arrowExample:
ESK
18
07
Identification characters
Day
Month
Manufacturing
year (2000)
The gearbox identification characters also appear on

the vehicle data stickers.
S37-0117
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Technical Data for the Gearbox
00-1 page 1
00
Identification characters, aggregate assignment, ratios, capacities

Automatic gearbox
Gearbox
001
ESK
GJF
GJG
Manufactured
07.00
11.02
12.02
12.02
from
through
Torque Converter
ACN
ACN
ACN
Slide valve body
CCC
CCC
CCC
Number of plates
Brake band
Inner
Outer
Inner
Outer
Inner
Outer
Clutch -K1-
Clutch -K2-
Clutch -K3-
Brake -B1-
Brake -B2- (2nd gear)

stepped piston in mm
Brake -B2- (4th gear)
single piston in mm
57 + 36
57 + 36
57 + 36
44
44
44
Assignment
Engine
1.4 ltr. - 55 kW
1.4 ltr. - 55 kW
1.4 ltr. - 55 kW
Ratios
1. Gear
2,875
2,875
2,875
2. Gear
1,510
1,510
1,513
3. Gear
1,000
1,000
1,000
4. Gear
0,726
0,726
0,726
Reverse
2,656
2,656
2,656
Input gear
49
49
39
Output gear
53
53
42
1,082
1,082
1,077
Drive pinion
20
20
20
Pinion final
drive
81
81
81
4,050
4,050
4,050
Intermediate gear
No. of teeth
Ratio
Final drive
No. of teeth
Ratio
Drive shaft flange
90 mm
Capacity
Planetary gear and final drive
Contents
New filling
5.7 ltr.
(filled for life)
Lubricant
ATF
Spare part no.:
G 052 990 A2
The oil filling is for the planetary gear and final drive together. Inspecting and filling Chapter 37-8.
00-1 page 2
Technical Data for the Gearbox
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Information and repair Instructions for the Automatic Gearbox 001
Information on the Automatic Gearbox

001
Information on this automatic gearbox can be found in
Self-study Programme No. 40; 4 speed automatic
gearbox 001.
Gearbox
The automatic 4 speed gearbox 001 is equipped with 4
hydraulically controlled forward gears. With the torque
converter lockup clutch closed the 3rd and 4th gear become mechanically driven gears by bypassing the converter slip.
Automatic Gearbox Control Unit -J217The control unit has two program options to meet the driver's preference for sporty (SPORT program) or for economic driving (ECO program).
These two programs are automatically selected in the
control unit.
Torque Converter
The torque converter is equipped with a torque converter
lockup clutch. The closing of the torque converter lockup
clutch is load and speed sensitive, and the torque converter lockup clutch can drive the 3rd and 4th gears mechanically (without slip).
ATF
The ATF is filled for life. The ATF need not be changed
within the scope of servicing.
Only use ATF with spare part number
G 052 990 A2
if ATF needs to be added.
The ATF oil filling is for the planetary gear and final drive
together. Inspecting and filling Chapter 37-8.
Repair instructions
Scrupulous care and cleanliness as well as the proper
tools are essential requirements for carrying out proper
and successful gearbox repairs. Obviously, the generally
valid basic safety rules apply to repair work.
A number of generally valid notes for individual repair operations - which are otherwise listed several times at numerous points in the workshop manual - are summarized
here. They apply to this workshop manual.
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Special tools
The composition of the special tools used in the workshop manual is listed in binder Workshop Equipment
Catalogue.
Gearbox
Do not run the engine or tow the vehicle when the oil
pan of the gearbox has been removed or without ATF

filling.
When replacing the automatic gearbox check the
ATF, if necessary top up Chap. 37-8. Capacities

and specification Chap. 00-1.
Secure the torque converter against dropping out
when the gearbox is removed.

Thoroughly clean the connection points and their sur-
roundings before releasing.

Before installing the gearbox check the fitting dimen-
sion of the torque converter Chap. 32-1.
When installing pay attention to the correct position of
the dowel sleeves.

Place removed parts on a clean surface and cover.
Use foil and paper. Do not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts. Remove spare parts from
their wrapping immediately before fitting.
O-rings, gasket rings, gaskets

Always replace O-rings, gaskets and gasket rings.
Before installing the gasket rings coat the outer cir-
cumference and sealing lips with ATF.

Before inserting the O-rings coat with ATF to prevent
the rings being squashed during installation.

Never use other lubricants in the ATF area.
After installation check ATF level, if necessary correct.
Sealant
Clean contact surfaces thoroughly and apply sealant
-D 176 404 A2-.

Pay attention to the sell-by-date of the sealant.
After applying the sealant screw the parts within 5
minutes.
After installing, allow the sealant to dry for about 30
minutes. Only then may ATF be filled in.
Locking elements
Do not over-extend the circlips, if necessary replace.
Circlips must be positioned in the base of the groove.
Replace roll pins. Fitting position: slot longitudinally to
power flow.
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Bolts, nuts
Slacken and tighten nuts and bolts for attaching cov-
ers and housings diagonally across.

Do not twist particularly sensitive parts - e.g. the slide
valve body - and slacken and tighten diagonally

across in stages.
Tightening torques apply for non-oiled nuts and bolts.
Clean the thread of the screws that are inserted with a
locking agent with a wire brush. Subsequently insert

screws with AMV 185 101 A1.
Replace the self-locking screws and nuts.
Bearings
Insert bearing in gearbox with ATF.
Insert the axial needle bearing in the correct fitting po-
sition Chap. 37-10.
Before inserting heat the inner rings of the tapered-
roller bearing to approx. 100C.

Do not mix up the outer and inner races of bearings of
the same size.

Always jointly replace tapered-roller bearings on the
same shaft and use products of the same manufacturer.
Piston rings
Do not overwind when removing and installing.
Shims
Gauge shims at several points with a micrometer. Dif-
ferent tolerances allow to measure the required thickness for each washer very precisely.
Inspect for burrs and damage. Install only shims which
are in perfect condition.
Inner plates
Place new inner plates in ATF for 15 minutes before
installing.
Slide valve body

The slide valve body must be replaced if the shift ele-
ments are burnt (plates).
Clutches
The clutches can be dismantled, assign defective
parts (e.g. outer and inner plates) according to their

gearbox identification characters.
Before installing the piston moisten the sealing lips
and gasket rings with ATF.
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After fitting it must be possible to turn the piston by
hand in the clutches or brakes in both directions -arrows-.

If this is not the case, the sealing lips or gasket rings
may block or be damaged.
If this defect occurs remove the piston.

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

After removing secure the brake band against spread-
ing open, e.g. with a self-adapted wire hanger -A-.
Self-diagnosis
Before repairing the automatic gearbox try to deter-
mine the origin of the damage as accurately as possible using self-diagnosis Rep. Gr. 01.
Explanation of the terms used in this

workshop manual.
The following explanations are only related to this assembly: Automatic Gearbox 001. They do not claim to be
generally applicable. Further information on these terms
can be found in Self-study Programme No. 40; 4speed Automatic Gearbox 001.
N38-0109
ATF (Automatic Transmission Fluid)

Gear oil for automatic gearbox
ATF-pump
Gear pump driven by the torque converter.
Brakes
They hold rotating parts in the gearbox. Automatic Gearbox 001 is fitted with a band and a plate brake. As opposed to the clutches the brakes are supported on the
gearbox housing.
Torque Converter
Transfers the engine torque to the automatic gearbox and
serves as an hydraulic starting clutch. The torque converter also includes the torque converter lockup clutch.
Self-diagnosis
The capability of the control unit to:
00-2 page 4
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recognize faults,
react to faults,
store faults,
Determine measured values and to display them in
the measured value block.
Free wheel/Stator
Ensures the torque increase in the torque converter when
starting.
Free wheel/Gearbox
Simplifies the technical effort of the gearshift without traction interruption and ensures a uniform gearshift quality.
Gearbox speed sender -G38The sender determines the speed of clutch -K3- and
sends it to the automatic gearbox control unit.
Vehicle speed sender -G68The sender determines the speed of the output gear and
sends it to the automatic gearbox control unit (not the
speedometer).
Gearbox oil temperature sender -G93Monitors the ATF temperature.
Clutches
Together with the brakes they shift the individual gears.
Selector lever lock solenoid -N110Located in the gearshift mechanism close to the selector
lever. Prevents the (unintentional) shifting of the selector
lever from positions P and N, as long as the brake
pedal is not pressed.
Solenoid valves
Open and shut the oil galleries to the clutches and
brakes.
Multi-function switch -F125Electric switch with different functions. Further information on this can be found in Self-study Programme
No. 40; 4 speed Automatic Gearbox 001.
Emergency running mode

Status of the control unit, to ensure further safe operation in the event of a detected faults, to protect the gearbox from damage and to thereby restrict the driving
behaviour as little as possible.
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00
Parking position
When the vehicle is standing the parking gear is block
mechanically thereby protecting the vehicle against (unintentional) rolling off.
Planetary gear
The mechanical part of the automatic gearbox that is
switched via clutches and brakes without power flow interruption.
Slide valve body

Located below the gearbox and is surrounded by the oil
pan of the gearbox. Its valves regulate the hydraulic pressure and distribute it via the oil galleries to the gearshift
elements (clutches and brakes).
Automatic Gearbox Control Unit -J217The electronic control unit determines the shifting points.
The function of the gearbox is monitored via self-diagnosis. If components or sensors fail an emergency running
programme is activated to maintain driveability.
LC (torque converter lockup clutch)

Mechanically transmits the engine torque to the gearbox.
00-2 page 6
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01
01 Self-diagnosis, Electrical Test

01-1
Function of Self-diagnosis
The control of the automatic gearbox is electronic/hydraulic.
The term self-diagnosis is related to this electric/electronic control.
Additionally required information means

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

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

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

The control unit detects faults while the vehicle is being
operated and stores them in the fault memory Chap.
01-4.
After analysing the information it makes a distinction between sporadic and currently present (static) faults and
stores them.
If the fault is not indicated for a given time or over a long
driving distance is becomes a sporadic fault.
A fault is also sporadic if the fault memory is not erased
after repair.
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During fault interrogation sporadic faults are displayed

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

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

mode
Line interruption, short-circuit, defective electric or hydraulic components.
Safety measures
If test and measuring devices are required during test
drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them

there. If the test and measuring devices are operated
from the passenger seat the passenger could be injured by the release of the passenger airbag in the
event of an accident.
Vehicle system tester -V.A.G 1552Functions, detected or performed by the vehicle system
tester -V.A.G 1552- Chap. 01-3.
Electrical faults that influence the driveability can be determined with vehicle system tester -V.A.G 1552-.
01-1 page 2
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Self-diagnosis technical data

Memory
Permanent memory
Volatile memory
yes
no
Data output
Vehicle system test
Flashing code output
yes
no
Final control diagnosis
no
Basic setting
yes Chap. 01-4
Coding control unit
no
Reading measured value

block
yes Chap. 01-5
Electric/Electronic compo- Chap. 01-2

nents and fitting locations
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01
01-1 page 4
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01-2
Vehicle components
Gearbox components 01-2 page 5
1 - Engine control unit
T Fitting location and removing
and installing Fig. 1 in
01-2 page 2
T Signal transfer occurs over
the data BUS drive
Note
2-
3-
4-
5-
6-
7-
89-
If the control units of the engine

or gearbox are replaced the system must be put into basic setting Chap. 01-4
Selector lever position display -Y6T Fitting location Fig. 7 in
9
01-2 page 4
T Signal transfer occurs over
the data BUS drive
Diagnostic connection
T Fitting location Fig. 2 in
8
01-2 page 2
Selector lever lock solenoid
-N110T Fitting location and removing
and installing Chap. 37-2
T is switched by the vehicle
voltage control unit -J519Brake light switch -FT Fitting location Fig. 4 in
7
01-2 page 3
T Signal transfer occurs via the
data BUS drive of the ABS
with EDL control unit -J104Relay for starter interlock switch -J207T Fitting location Fig. 5 in 01-2 page 3
T is switched by the vehicle voltage control unit -J519Accelerator pedal position sender -G79T Fitting location and removing and installing Fig. 3 in 01-2 page 2
T generates the kick-down signal
T Signal transfer occurs over the data BUS drive of the engine control unit
Gearbox
T Electric/electronic components of the gearbox 01-2 page 5
Automatic Gearbox Control Unit -J217T Fitting location Fig. 6 in 01-2 page 3
T removing Fig. 6 in 01-2 page 3
T Control unit is checked by self-diagnosis Chap. 01-3
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4
S01-0102
01-2 page 1
01
Fitting locations
Fig. 1:
Engine control unit
Fitting location: The control unit is located at bulkhead.

Removing and installing the control unit Engine,
Fuel Injection; Rep. Gr. 24
S24-0373
Fig. 2:
Diagnostic connection
Fitting location: The diagnostic connector is located behind the storage area -arrow- on the driver's side.
S01-0104
Fig. 3:
Accelerator pedal position sender -G79-
Fitting location: The accelerator pedal position sender

-G79- -arrow- is a component part of the gas pedal.
The accelerator pedal position sender -G79- generates
the Kick-down signal, when the accelerator pedal is
suddenly pressed down fully.
For self-diagnosis
Signal can only be checked in the measured value block
Chap. 01-5.
Removing and installing accelerator pedal position
sender -G79 Engine, Mechanics; Rep. Gr. 20
01-2 page 2
S01-0105
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Fig. 4:
Brake light switch -F-
Fitting location: The brake light switch -F- -arrow- is located in the foot controls.
For self-diagnosis
Signal can be checked in the measured value block
Chap. 01-5.
Removing and installing the brake light switch
Running gear; Rep. Gr. 45
S01-0107
Fig. 5:
Relay for starter interlock switch -J207-
Fitting location: The relay is located on the relay carrier

-1- above the vehicle voltage control unit -2-.
The relay carrier is located behind the storage area on

the driver's side.
The relay is identified with number 53.
Removing and installing the relay
Remove the storage area on the driver's side Body
Work; Rep. Gr. 68.
Remove the relay from the relay carrier.

S01-0108
Fig. 6:
Automatic Gearbox Control Unit -J217-
The control unit -arrow- is located behind the battery on

the battery tray.
Removing the control unit
Switch off ignition, open engine compartment cover.

Unlock the multi-pin connector and unplug it from the
control unit.
S01-0111
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01
Release the two screws -arrows- and remove the control unit.
The installation occurs in reverse order.
Initiate basic setting Chap. 01-4.

Perform self-diagnosis Chap. 01-3.
S01-0109
Fig. 7:
Selector lever position indicator -Y6-
Fitting location: in the dash panel insert

Removing and installing: Electrical System;
Rep. Gr. 90
For self-diagnosis:
In the event of emergency running mode and if the control
unit is operational all segments of the selector lever position indicator -Y6- light up in the dash panel insert.
In the event of emergency running mode and if the control
unit fails there is no indication of the selector lever positions.
S01-0103
S01-0108
01-2 page 4
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Electric/electronic components of the gearbox

1 - 6 Nm
2 - Wiring loom
3 - Vehicle speed sender -G68T with connection cable
01-2 page 6
T is checked by self-diagnosis
4 - 6 Nm
5 - 6 Nm
6 - Gearbox speed sender -G38T with connection cable
01-2 page 6
7 - Gearbox
8 - Wiring loom
T for the solenoid valves and
gearbox oil temperature
sender -G93T Fitting location and removing
01-2 page 5
9 - Multi-function switch -F125T adjust Fig. 10 in 01-2
page 6
10 - 3 Nm
11 - Lever
T for gearshift shaft
12 - 17 Nm
1
2
3
4
5
6
7
10
9
12
10
11
S37-0059
Fitting locations
Fig. 8:
Wiring loom for the solenoid valves and

gearbox oil temperature sender -G93-
Fitting location: The wiring loom is located in the oil pan

under the slide valve body.
Removing and installing the wiring loom
The wiring loom can be replaced with the gearbox mounted without having to remove the slide valve body.
S37-0066
Edition 07.00
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01-2 page 5
01
Drain ATF Chap. 37-8.

Removing the oil pan Chap. 38-2.
Disconnect the plug connection at gearbox.

Unlock the connector -arrows- and remove from gearbox housing.
Unclip gearbox oil temperature sender -G93- -3-.

Release plug connection -4- from the solenoid valve 6
-N93-.
Disconnect the plug connection -1- for the solenoid

valves.
Unhook the wiring loom from the holder -2-.

S37-0083
Clean the sealing surface of the oil pan at the gearbox

and at the oil pan and coat with sealant:
D176 404 A2
when installing Chap. 37-11.
Top up ATF Chap. 37-8.

Tightening torques:
Oil pan at gearbox: 8 Nm
Fig. 9:
Gearbox speed sender -G38- and vehicle

speed sender -G68-
Fitting location: The sender is located at the top of the

gearbox.
-A- -G38- with connection cable
S37-0065
-B- -G68- with connection cable

Removing and installing sender
R
N
D
3
2
Disconnect the plug connection at wiring loom.

Remove screw, pull out sender.
Replace O-ring.
Tighten screw to 6 Nm.
Fig. 10: Adjust multi-function switch.
Requirements
Adjustment of the selector lever control cable O.K.

Chap. 37-4
Selector lever in N
Screws -arrows- released
Insert a 4 mm drill bit -A- through the gearshift lever in
the adjusting hole of the multi-function switch.
Tighten screws -arrows- on the multi-function switch

in this position to 3 Nm.
S37-0060
Remove drill bit.
01-2 page 6
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01
01-3
Performing self-diagnosis
Special tools, test and measuring equipment and

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

Connect vehicle system tester -V.A.G 1552- with the
diagnostic cable -V.A.G 1551/3Once the vehicle system tester has been connected:
V.A.G 1552
Switch on ignition or start engine depending on the
V.A.G 1551/3
desired function.
Note
S01-0087
If because of an input error data transfer fault is dis-
played, remove the cable from the vehicle system

tester, re-connect and repeat the steps.
If one of the following messages appears in the dis-
play, carry out fault finding as specified in the fault

finding program diagnostic cable. Current flow diagrams, fault finding electrical system, fitting locations
or operating instructions of the vehicle system tester.
Vehicle system test

HELP
The control unit does not respond
Vehicle system test

HELP
Fault in communication set-up
Vehicle system test
HELP
K cable does not connect to earth
Operate the vehicle system tester by following the in-
Vehicle system test

HELP
K cable doest not connect to pos. term.
dication on the display:

Vehicle system test
Enter address word XX
Read-out on display:
Press
HELP
0 and 2 for address word 02 and confirm the
entry with Q .
The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.:
001927731H
AG4
Gearbox
001 JEG2944 ->
Control unit identification

Depending on the fitting status (program status) the control unit may indicate a different control unit identification
Edition 07.00
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01-3 page 1
01
than the one shown in this example. Assignment of the

control unit Spare part catalogue.
001927731H = Part No. of the control unit (for current
control unit version see spare parts catalogue)

AG4 Gearbox 001 = Automatic gearbox 4 speed 001
2944 = Data status (Software version of the control
unit)
Press
.
Vehicle system test
Select function XX
HELP
Further procedure, see repair sequences.

After pressing
HELP an overview of the possible func-
tions is displayed.
Overview of selectable functions

Operation
Page
01 - Interrogating control unit ver- 01-3 page 1

sion Performing self-diagnosis
02 - Interrogating fault memory
01-3 page 2
04 - Initiating basic setting
Chap. 01-4
05 - Erasing fault memory
01-3 page 2
06 - Ending output
08 - Reading measured value
block
Chap. 01-5
Interrogating and erasing fault memory

Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Switch

on the ignition and select the gearbox control unit with
Address word 02 01-3 page 1.
Press
0 and 2 for the function Interrogate fault
memory and confirm the entry with Q .

The display shows the number of faults stored in the
memory or no fault detected! . will be displayed.
X faults detected
If no fault is stored in the memory:
Select function 06 End output and confirm entry with

Q.
If one or more faults are stored in the memory:
Press
01-3 page 2
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01

Read-out of fault number on display, e.g.:
Press
->
Fault number: 00258
Read-out of fault source with fault type on display, e.g.:
Press
035
Solenoid valve 1 -N88

Short-circuit to earth
->
Vehicle system test

Fault memory erased
->
The stored faults are displayed in sequence.

Q.
Refer to the fault table to remove the indicated faults

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

The -V.A.G 1552- sends all known address words in sequence.
Erasing fault memory

Test conditions
Fault eliminated
Fault memory interrogated 01-3 page 2.
Note
After fault elimination the fault memory must again be interrogated and subsequently erased.
Press
0 and 5 for the function Erase fault memory
and confirm the entry with Q .

Note
If the ignition has been switched off between interrogate
fault memory and erase fault memory, the fault memory will not be erased.

Q.
Perform a test drive. Again interrogate the fault memory. No fault must be displayed.
Note
Comply with the safety instructions for test drives
Chap. 01-1.
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01-3 page 3
01
01-3 page 4
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01
01-4
Fault Table and Initiating Basic Setting
Fault table
Note
The fault table is ordered according to the 5-digit fault code on the left.
If parts are output as faulty: First check the cables and connectors to these parts as well as the earth leads of the
system by referring to the current diagram. Only if no fault is detected here should the part be replaced. This applies
in particular for faults that are output as sporadically occurred(SP) faults.
If the display of the vehicle system tester -V.A.G 1552- reads Documentation, the required text is to be found in
the fault table according to the fault code.

Read-out on -V.A.G 1552-
Possible cause of fault
Rectifying fault
Open circuit/
00258
Short-circuit to
Solenoid valve 1 -N88pos. term.
Line interruption
Short-circuit to
earth
Short-circuit to
earth
Short-circuit to
earth
Line interruption
Line short-circuit to earth or
positive
Solenoid valve 2 -N89- de Line interruption
positive
Solenoid valve 3 -N90- de-
fective
00264
Open circuit/
Solenoid valve 4 -N91Short-circuit to
pos. term.
Short-circuit to
earth
Line interruption
positive
fective
00266
Open circuit/
pos. term.
Short-circuit to
earth
Line interruption
positive
fective
00268
Open circuit/
pos. term.
Short-circuit to
No signal
fective
00262
Open circuit/
pos. term.
00281
Vehicle speed sender
-G68-
positive
fective
00260
Open circuit/
pos. term.
earth
Line interruption
positive
fective
Line interruption or short-cir-
cuit to earth
Vehicle speed sender -G68-
defective
block, display group number

004 Chap. 01-5.
Performing electrical test, test

step 5 Chap. 01-7.

004 Chap. 01-5.

step 6 Chap. 01-7.

004 Chap. 01-5.

step 7 Chap. 01-7.

003 Chap. 01-5.

step 8 Chap. 01-7.

004 Chap. 01-5.

step 9 Chap. 01-7.

004 Chap. 01-5.

step 10 Chap. 01-7.

003 Chap. 01-5.

step 3 Chap. 01-7.
Replacing vehicle speed
sender -G68- Chap. 01-2.
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01-4 page 1
01
Read-out on -V.A.G 155200293

Multi-function switch
-F125-
undefined switch
status
Rectifying fault
Line interruption
Multi-function switch -F125-
No signal
not adjusted
defective

004 Chap. 01-5.
Adjusting multi-function switch

-F125- Chap. 37-4.

step 2 Chap. 01-7.
00296
Kick-down switch -F8-
Short-circuit to
earth
Line interruption
Accelerator pedal position
sender -G79- defective

Data BUS defective

004 Chap. 01-5.
Inspecting accelerator pedal

position sender -G79 Engine, Fuel Injection;
Rep. Gr. 24.
Testing data BUS Electrical

system; Rep. Gr. 90.
00297
Gearbox speed sender -G38-
No signal
Line interruption
Gearbox speed sender
-G38- defective

001 Chap. 01-5.

step 4 Chap. 01-7.
00300
Gearbox oil temperature sender -G93-
Open circuit/
Short-circuit to
pos. term.
Line interruption
Gearbox oil temperature

002 Chap. 01-5.

step 11 Chap. 01-7.
00350
Earth return Modulation valves
Outlet does not
connect/Shortcircuit to positive
Line interruption
Automatic gearbox control
unit -J217- defective
Check wiring and plug connections according to the current flow diagram Current
Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
Replacing control unit

Chap. 01-2.
Put system in basic setting

01-4 page 4
00526
Brake light switch -F-
Short-circuit to
positive terminal
Line interruption
Brake light switch -F- defec-
tive
Data BUS defective

004 Chap. 01-5.

Inspecting brake light switch

-F- Running Gear;
Rep. Gr. 45.
00529
Speed information
missing
No signal
Line interruption
Data BUS defective

001 Chap. 01-5.
Inspecting engine control unit

Engine, Fuel Injection;
Rep. Gr. 01.

01-4 page 2
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01

Engine/gearbox electrical connection
Open circuit/
Short-circuit to
earth
Short-circuit to
positive terminal
Rectifying fault
cuit
no connection engine/gear-
box control unit

the signal for the ignition-tim-
ing adjustment is not or incorrectly transmitted from

the engine to the gearbox
control unit
00652
Gear monitoring
Implausible sig-
nal

125 Chap. 01-5.

Rep. Gr. 01.

Data BUS defective
electric/hydraulic fault
While driving determine in
Clutch or slide valve body
defective
01-4 page 4
which gear the fault occurs.
Carry out fault finding according to fault finding table

Chap. 37-3.
00777
Accelerator pedal position sender -G79-
No signal
Line interruption
Accelerator pedal position

Data BUS defective

003 Chap. 01-5.

Inspecting accelerator pedal

position sender -G79 Engine, Fuel Injection;
Rep. Gr. 24.
01166
Signal for engine
torque
01192
Clutch for torque converter lockup
Implausible sig-
nal
Line interruption
the signal for the engine
torque is not or incorrectly

transmitted from the engine
to the gearbox control unit
Clutch for torque
converter lockup
defective
mechanical fault
Line interruption
Lockup clutch slips
fective
Slide valve body defective
01236
Selector lever lock solenoid -N110-
Short-circuit to
earth
cuit to earth
Open circuit/
Short-circuit to
pos. term.
Selector lever lock solenoid
-N110- defective
Vehicle voltage control unit
-J519- defective

Rep. Gr. 01.


003 Chap. 01-5.

step 8 Chap. 01-7.

004 Chap. 01-5.
Inspecting vehicle voltage

control unit -J519 Electrical System;
Rep. Gr. 90.
Replacing selector lever lock
solenoid -N110- Chap. 376.
01312
Data BUS drive
defective
Data BUS wires and plug
no communica-
tion
connections defective
Control units on data BUS
defective or incorrectly coded
Edition 07.00
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Inspecting control units at
data BUS Engine, Fuel Injection; Rep. Gr. 01
01-4 page 3
01

4AV Control unit
no communica-
tion
Rectifying fault

Rep. Gr. 01.
wrong equip-
ment
Fault in system engine

Engine control unit possibly
incorrectly coded
01316
Brake control unit
no communica-
tion
Inspecting ABS control unit

Running Gear;
Rep. Gr. 45.
Fault in ABS system

Control unit de-
65535
fective
Automatic gearbox control
Replacing control unit

Chap. 01-2.
unit -J217- defective

01-4 page 4.
Only after having determined the possible cause of the fault and having eliminated the following faults:
mechanical fault
hydraulic fault
or affected electric/electronic components and wiring
should the automatic gearbox control unit -J217- be replaced Chap. 01-2, and the system be put in basic setting
01-4 page 4.
Initiating basic setting

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

address word 02 gearbox electronics and keep
switching until select function XX is displayed
Chap. 01-2
Vehicle system test
Select function XX
Press
HELP
0 and 4 for the function initiating basic set-
ting.
Note
Do not activate the accelerator pedal yet.
Vehicle system test
04 - Basic setting
Confirm the entry with
Q.
Basic setting
Enter display group number XXX
Press keys
0 , 0 and 0 .
Confirm the entry with
01-4 page 4
Q.
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01

System in basic setting
0->
This puts the system in basic setting.
Depress accelerator pedal up to kickdown and maintain in this position for 3 seconds.
press.
Vehicle system test

Select function XX
HELP
Release accelerator pedal again
Edition 07.00
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01-4 page 5
01
01-4 page 6
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01
01-5

block

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

on the ignition and select the gearbox control unit with
Address word 02 Chap. 01-1.
Vehicle system test
Select function XX
HELP
Press
0 and 8 for the function Read measured value block and confirm with Q .
Reading measured value block
Enter display group number 01-5 page 1.

Further procedure, see repair sequences.
List of display groups

Read-out on display (example)
Display
group
number
Reading measured value block 1

20 km/h
1500 rpm
1520 rpm
001
Display
field
1
2
3
4

0%
35 %
30.0 C
20 km/h
0%

D
00001000
01000000

Engine 1
ABS 1
12.5 V
002
3
4
003
004
1
2
3
4
Selector lever position

multi-function switch
switch positions
shift outputs
125
Engine control unit at data

BUS
ABS control unit at data
BUS
dash panel insert at data
BUS
not assigned
Combi 1
3
4
Edition 07.00
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Accelerator pedal value

solenoid valve 6 -N93- (adjustment in %)
ATF temperature
battery voltage
2
3
4
00000110
Vehicle speed sender -G68gearbox speed sender

-G38engine speed
gear engaged
Vehicle speed sender -G68accelerator pedal value

gear engaged
solenoid valve 4 -N91- (adjustment in %)
4%
1
2
Denomination
01-5 page 1
01
If the nominal values are reached in all display fields:
press.
Vehicle system test
Select function XX
HELP
Press
0 and 6 for the function End output and confirm with Q .
Test table
Display
group
numb
er
001
Dis- Denomination
play
field
Vehicle speed
sender -G68-
Test conditions
while driving
Display on Measures for deviations from nomiV.A.G. 1552 nal value
...km/h
The display in the dash panel insert and

the values on V.A.G. 1552 may differ
slightly from one another.
Inspecting vehicle speed sender

-G68- Chap. 01-7.
2
3
Gearbox speed with engine running

sender -G38while driving
.../min
Engine speed
.../min
with engine running
Inspecting gearbox speed sender

-G38- Chap. 01-7.

Perform self-diagnosis of engine
control unit Engine, Fuel Injection; Rep. Gr. 01.
Testing data BUS Electrical system; Rep. Gr. 90.
01-5 page 2
gear engaged
Inspecting solenoid valve Chap.
while driving
Neutral
Reverse (up
to approx. 10
km/h)
1 hydraulic
2 hydraulic
3 hydraulic
3H
3 mechanic
3M
4 hydraulic
4H
4 mechanic
4M
01-7.
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01

Display
group
numb
er
002
Dis- Denomination
play
field
2
3
Accelerator
pedal value
Test conditions
at standstill
Idling
0....1 %
Full throttle
90 %
Kickdown
99 %
Solenoid valve
6 -N93-
at standstill
Idling
ATF temperature
the ATF level is
checked at a
temperature of
35...45 C
in idle
the exact display of the
temperature only occurs
above approx. 30 C.
Full throttle
Battery voltage at standstill
0...25 %
88...100 %
... C
When accelerating from idle to full throttle the %-value increases constantly.
Inspecting accelerator pedal position sender -G79- Engine, Fuel

Injection; Rep. Gr. 23 oder 24.
Perform basic setting Chap. 01-4.

Inspecting solenoid valve 6 -N93 Chap. 01-7.
Inspecting gearbox oil temperature

sender -G93- Chap. 01-7.
min.
11.5 V
max.
14.4 V
Testing voltage supply Chap. 017.
Check battery Electrical System;

Rep. Gr. 27.
003
Vehicle speed
sender -G68-
While driving
...km/h

Inspecting vehicle speed sender

-G68- Chap. 01-7.
Accelerator
pedal value
gear engaged
Solenoid valve
4 -N91-
at standstill
Idling
Full throttle
90 %
Kickdown
99 %
Neutral
Reverse (up
to approx. 10
km/h)
1 hydraulic
2 hydraulic
3 hydraulic
3H
3 mechanic
3M
4 hydraulic
4H
4 mechanic
4M
Inspecting accelerator pedal position sender -G79- Engine, Fuel

Injection; Rep. Gr. 23 oder 24.
01-7.
Inspecting solenoid valve 4 -N91-
while driving
hydraul. Gear
When accelerating from idle to full throttle the %-value increases constantly.

Inspecting solenoid valve Chap.
while driving
mech. Gear
Edition 07.00
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0...1 %
4...6 %
Chap. 01-7.
94...96 %
01-5 page 3
01
Display
group
numb
er
004

Dis- Denomination
play
field
Selector lever
position
Multi-function
switch -F125-
Test conditions
Inspecting selector lever

in
Chap. 01-7.
Inspecting selector lever

in
Chap. 01-7.
00000001
00000010
00000100
00001000
00010000
00100000
01000000
ignore first six positions
Kick-down signal
Inspecting accelerator pedal position
Kick-down signal
7. Position
available
not available
sender -G79- Engine, Fuel Injection; Rep. Gr. 23 oder 24.
Brake light
switch -F-
01-5 page 4
Inspecting brake light switch -F-
Brake
8. Position
activated
not activated
Running Gear; Rep. Gr. 45.
Edition 07.00
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01

Display
group
numb
er
004
Dis- Denomination
play
field
Solenoid valve
4 -N91- for
lockup clutch
1. Position
Selector lever
lock solenoid
-N110-
Deactivation of
air conditioning
Ignition-timing
adjustment
Edition 07.00
S00.5318.00.20
Test conditions
activated
not activated
2. Position
selector
lever in
P
or in N
engaged
Activate
brake or
selector
lever in
R, D,
3, 2, 1
switched off
3. Position
is switched
off
is not
switched off
switched on
(only displayed when
shifting
gears)
switched off
activated
not activated
activated
not activated
activated
not activated
activated
not activated
4. Position
Solenoid valve
3 -N90-
5. Position
Solenoid valve
5 -N92-
6. Position
Solenoid valve
2 -N89-
7. Position
Solenoid valve
1 -N88-
8. Position
Inspecting selector lever lock solenoid -N110- Chap. 37-6.
Inspecting brake light switch -F Running Gear; Rep. Gr. 45.
Testing air conditioning system
Air conditioning; Rep. Gr. 87.
01-5 page 5
01
Display
group
numb
er
125

Dis- Denomination
play
field
Engine control
unit
Test conditions
Engine
at data BUS
not at data
BUS
ABS control
unit
ABS
at data BUS
not at data
BUS
Perform self-diagnosis of ABS
Running Gear; Rep. Gr. 45.
Dash panel insert
Combi
at data BUS
not at data
BUS
Perform self-diagnosis of the dash

panel insert Electrical System;
Rep. Gr. 90.
01-5 page 6
not assigned
Edition 07.00
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01
01-6
Inspecting the solenoid

valves and shift elements
while driving
The solenoid valves and shift elements can be inspected

while driving in measured value block 08, display group
004 ( Chap. 01-5).
Observe the safety instructions in Chap. 01-1.

The table indicates the activated solenoid valves -
N88-, -N89- and -N92- in the individual gears. They

control the position of the corresponding shift elements in the gears.
Solenoid valve -N91- controls the modulation valve for
the lockup clutch.

Solenoid valves -N90- and -N93- are valves that influ-
ence gearshifting indirectly to offer great shifting comfort. -N90- = time delay valve, -N93- = main pressure
valve (is not displayed in display group number 004).
Note
The display on vehicle system tester -V.A.G 1552- is
8-digit (e.g.: 01000011).

Only consider positions 1, 3, 7 and 8.
Test conditions
Selector lever in position D

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

Solenoid valves
Gear
N91
Disregard display
Shift elements
N92
N89
N88
K1
K2
K3
B1
B2
3H
3M
4H
4M
LC
X
X
X
X
X = closed shift element

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

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

Binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations Fabia 2000

Test requirements
Battery voltage at least 11.5 volts

Fuses according to current flow diagram O.K.
Earth connections O.K.
Test procedure
The automatic gearbox control unit -J217- -arrow- is located on the battery tray.
S01-0111
Switch off ignition, unlock multi-pin connector and remove from automatic gearbox control unit -J217-.
Plug adapter cable -V.A.G 1598/18-A- into the multipin connector -arrow 1- and lock in -direction of arrow
2-.
V.A.G
1598/18
The adapter cable -V.A.G 1598/18-A- allows to check the

wiring according to the Current Flow Diagram.
Set the correct measuring range on the measuring

tool before connecting the measuring cables. Otherwise the electronic components may be destroyed!
The indicated nominal values apply for an ambient
temperature of 0 C to 40 C.
If the measured values deviate from the nominal val-
ues, determine fault according to Current Flow Diagram.
N37-0139
If the measured values only differ slightly from the
nominal values, clean the bushes and plugs of the test

devices and measuring cables and repeat test. Before
replacing the relevant components check their wiring
and connections. Specifically for nominal values below 10 repeat resistance measurement on component.
Edition 04.05
S00.5318.02.20
Electrical Test
01-7 page 1
01
Multi-pin connector of the automatic gearbox control unit -J217- (bushes on -V.A.G 1598/18-)
Earth (terminal 31)
35
not assigned
36
not assigned
37
not assigned
not assigned
38
not assigned
K cable of diagnosis
39
not assigned
not assigned
40
Multi-function switch -F125- (position R)
not assigned
41
Multi-function switch -F125- (position N)
not assigned
42
Multi-function switch -F125- (position P)
43
Multi-function switch -F125- (position 3)
10
44
Multi-function switch -F125- (position D)
11
not assigned
45
Power supply (terminal 15)
12
not assigned
46
not assigned
13
not assigned
47
not assigned
14
not assigned
48
Solenoid valve 1 -N88-
15
Data BUS high
49
16
Data BUS low
50
17
not assigned
51
not assigned
18
52
not assigned
19
53
not assigned
20
not assigned
54
not assigned
21
not assigned
55
not assigned
22
Power supply (terminal 30)
56
not assigned
23
not assigned
57
not assigned
24
not assigned
58
not assigned
25
59
not assigned
26
60
not assigned
27
not assigned
61
not assigned
28
not assigned
62
not assigned
29
not assigned
63
not assigned
30
not assigned
64
Earth return (for valve diagnosis)
31
not assigned
65
not assigned
32
not assigned
66
Power supply for solenoid valve 5 -N92-
33
Gearbox oil temperature sender (ATF) -G93-
67
not assigned
34
Gearbox oil temperature sender (ATF) -G93-
68
Terminal 15 outlet for multi-function switch

-F125-
Overview of test steps

Only perform the test steps listed per component in
the fault table and the measured value block.
01-7 page 2
Electrical Test
Edition 04.05
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01
Tested component
Test step
Tested component
Test step
Perform test step 1
Perform test step 7
Perform test step 2

Vehicle speed sender -G68- Perform test step 3
Gearbox speed sender
Perform test step 4
Perform test step 8

Perform test step 9
Perform test step 10
Power supply for automatic

gearbox control unit -J217Multi-function switch -F125-
Solenoid valve 5 -N92Solenoid valve 6 -N93-
-G38Solenoid valve 1 -N88Solenoid valve 2 -N89-
Perform test step 5

Perform test step 6
Gearbox oil temperature

sender -G93-
Perform test step 11
Test table
Switch on measuring range: Voltage measurement (20V=)

Test
step
Adapter cable
-V.A.G 1598/
18- bushes
Test covers
Test conditions Specification
Measures for deviations

from nominal value
additional
works
22 + 1
Supply voltage for the

automatic gearbox
control unit -J217(terminal 30)
Ignition off
approx. battery voltage
Test cable from contact
1 to earth Current
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.

22 to terminal 30
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
Check battery
Electrical System;
Rep. Gr. 27.
45 + 1
Supply voltage for the

automatic gearbox
control unit -J217(terminal 15)
Ignition off
1 to earth Current
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.

45 to terminal 15
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
Check battery
Electrical System;
Rep. Gr. 27.
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Electrical Test
01-7 page 3
01
Switch on measuring range: Voltage measurement (20V=)

Test
step
Adapter cable
-V.A.G 1598/
18- bushes
Test covers

from nominal value
additional
works
68 + 1
-F125-
Ignition on
42 + 1
-F125-
Selector lever
position P
Selector lever
0- 1 V
position R, N,
D, 3, 2, 1
40 + 1
-F125-
Selector lever
-F125-
position R
Selector lever
0-1V
Selector lever
on multi-function switch
for contact corrosion if
necessary replace.
Adjusting multi-function
switch Chap. 37-4.
Check wiring from auto-
position P, N,
D, 3, 2, 1
41 + 1
Check plug connection
matic gearbox control

unit -J217- to the multifunction switch -F125 01-7 page 6.
Replacing multi-func-
position N
Selector lever
0-1V
tion switch -F125 Chap. 37-4.
position P, R,
D, 3, 2, 1
44 + 1
-F125-
Selector lever
position D
Selector lever
0-1V
position P, R,
N, 3, 2, 1
43 + 1
-F125-
Selector lever
position 3
Selector lever
0-1V
position P, R,
N, D, 2, 1
19 + 1
-F125-
Selector lever
position 2
Selector lever
0-1V
position P, R,
N, D, 3, 1
18 + 1
-F125-
Selector lever
position 1
Selector lever
0-1V
position P, R,
N, D, 3, 2
01-7 page 4
Electrical Test
Edition 04.05
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01
Switch on measuring range: Resistance measurement (20 k)

Test
step
Adapter cable
-V.A.G 1598/
18- bushes
Test covers

from nominal value
additional
works
35 + 36

-G68-
min.
0.4 k
max.
0.6 k

unit -J217- to the vehicle speed sender -G68prfen 01-7 page 6.
Replacing vehicle
speed sender -G68 Chap. 01-2.
4
9 + 10
min.
0.4 k
max.
0.6 k

unit -J217- to the gearbox speed sender -G38check 01-7 page 6.
Replacing gearbox
speed sender -G38 Chap. 01-2.
Switch on measuring range: Resistance measurement (200 )

Test
step
Adapter cable
-V.A.G 1598/
18- bushes
Test covers

from nominal value
additional
works
48 + 1
Solenoid valve 1
-N88-
Ignition off
924
49 + 1
Solenoid valve 2
-N89-
Ignition off
924
50 + 1
Solenoid valve 3
-N90-
Ignition off
924
26 + 1
Solenoid valve 4
-N91-
Ignition off
924
66 + 1
Solenoid valve 5
-N92-
Ignition off
924
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Electrical Test
Check wiring from automatic gearbox control

unit -J217- to the solenoid valve 01-7
page 6.
Replacing solenoid
valve Chap. 38-8.
01-7 page 5
01
Switch on measuring range: Resistance measurement (20 k)

Test
step
Adapter cable
-V.A.G 1598/
18- bushes
Test covers

from nominal value
additional
works
10
25 + 1
Solenoid valve 6
-N93-
Ignition off
924
Check wiring from automatic gearbox control

unit -J217- to the solenoid valve 01-7
page 6.
Replacing solenoid
valve Chap. 38-8.
11
33 + 34
Gearbox oil temperature sender -G93-
Ignition off
ATF tempera-
ture
approx. 30 C
2.2 k
approx. 70 C
0.5 k
approx. 110 C
0.2 k

unit -J217- to the gearbox oil temperature
sender -G93- prfen
01-7 page 6
Replacing gearbox oil

temperature sender
-G93- Chap. 01-2.
After the electrical test
Connect the multi-pin connector -arrow 1- to the pins
of the automatic gearbox control unit -J217- and subsequently lock the multi-pin connector -arrow 2-.
Note
When inserting make sure the guides are placed on the
control unit pins.
1
Check the wiring between the automatic
gearbox control unit -J217- and the gearbox
N37-0292

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

01-7 page 6
Electrical Test
Edition 04.05
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01
Plug connections on gearbox
1234-
68-pin plug to automatic gearbox control unit -J2172-pin plug to vehicle speed sender -G682-pin plug to gearbox speed sender -G388-pin plug to the solenoid valves and to the gearbox
oil temperature sender -G935 - 10-pin plug to the multi-function switch -F125-
1
3
4
Switch off ignition, unlock multi-pin connector and remove from automatic gearbox control unit -J217-.
Remove battery and battery tray. Electrical system;
S01-0110
Rep. Gr. 27.
Plug adapter cable -V.A.G 1598/18-A- into the multi-
pin connector -1- and lock in direction of arrow -2-.
V.A.G
1598/18
N37-0139
Inspect wiring to the vehicle speed sender -G68-
Disconnect the 2-pin plug connection and check the

wiring for interruption.
S37-0063
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Electrical Test
01-7 page 7
01

-G68-
Adapter cable
-V.A.G 1598/18- bushes
Specification
Measures for deviations from nominal value
35
less than 1.5
Remove line interruption according
36
less than 1.5
to Current Flow Diagram

Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Check plug for:

Contact corrosion
Water penetration
Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the vehicle speed sender -G68- Chap.
01-2.
Inspect wiring to the gearbox speed sender

-G38-
Disconnect the 2-pin plug connection and check the

wiring for interruption.
S37-0062

Adapter cable
Specification
less than 1.5
10
less than 1.5

Check plug for:

Contact corrosion
Water penetration
Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the gearbox speed sender -G38- Chap.
01-2.
01-7 page 8
Electrical Test
Edition 04.05
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01
Inspect wiring to the plug of the solenoid valves

and to the gearbox oil temperature sender -G93-
Disconnect the 8-pin plug and check the wiring for in-
terruptions.
S37-0061

Plug to the solenoid valves
and to the gearbox oil temperature sender -G93-
Adapter cable
-V.A.G 1598/18bushes
Specification
48
less than 1.5
49
less than 1.5
26
less than 1.5
66
less than 1.5

25
less than 1.5
Check plug for:
33
less than 1.5
34
less than 1.5
Contact corrosion
7
8
50
less than 1.5
Water penetration
Leakage
Note
If this test of the wiring does not show any unauthorised deviations, replace the gearbox oil temperaturesender
-G93-,the wiring in the slide valve body or the solenoid valves Chap. 01-2.
Inspect wiring to the multi-function switch

-F125-
Disconnect the 10-pin plug and check the wiring for interruptions.
10
S37-0064
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Electrical Test
01-7 page 9
01

-F1251
2
Adapter cable
Specification
Pins 1 and 2 are not connected to the automatic

gearbox control unit -J217-.
Measures for deviations from

nominal value
Remove line interruption according to Current Flow Diagram

Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations.
68
less than 1.5
42
less than 1.5
40
less than 1.5
41
less than 1.5
Check plug for:
44
less than 1.5
Contact corrosion
43
less than 1.5
Water penetration
19
less than 1.5
Leakage
10
18
less than 1.5
Note
If this test of the wiring does not show any unauthorised deviations, replace the multi-function switch -F125- Chap.
01-2.
01-7 page 10
Electrical Test
Edition 04.05
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32
32 Torque Converter
32-1
Torque Converter
Identification of the torque converter

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

(Gearbox installed)
Remove cover plate -arrow-.
S32-0007
Draining the torque converter

The torque converter must be drained if the ATF is soiled
by metal swarf or if the gearbox is submitted to a major
overhaul.
Removing and installing gasket ring for

torque converter
Drive bushing -T30024 Ejection lever -MP 3-418-
N32-0024
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Torque Converter
32-1 page 1
32
Removing gasket ring for torque converter
MP 3-418
S32-0008
Insert the gasket ring for torque converter until flush
Installing the torque converter

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

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

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

The converter is correctly installed if the dimension between the screw-on flange of the gearbox housing and
the contact surface guide studs of the converter is of 18
mm.
N32-0030
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Torque Converter
32-1 page 3
32
32-1 page 4
Torque Converter
Edition 07.00
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37
37 Control, housing
37-1
Checking shifting points
Before checking the shifting points
Perform self-diagnosis and eliminate any faults.

if necessary initiate basic setting.
Checking ATF level Chap. 37-8.
Inspecting engine adjustment Workshop Manual of
the relevant engine.
Gearbox shifts too soon or too late to the next gear

When inspecting the shifting points take into account that
the speedometer may deviate from the nominal value
within the authorised tolerance.
To inspect the shifting points connect -V.A.G 1552 Chap. 01-3.
H = Hydraulic shift (with converter slip)
M = Mechanical shift (without converter slip)
Position of the shift elements in the individual gears
Chap. 01-6.
Only the kick-down shifting points are indicated.
Shifting points in km/h
1)
Gearbox identification characters Automatic Gearbox 001
Gearshifts
Kickdown
km/h1)
ESK
1H-2H
3642
2H-3H
7581
3H-3M
7581
3M-4H
122128
4H-4M
122128
While driving: The assistance of a second mechanic is required to read off the nominal values.
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37-1 page 1
37
37-1 page 2
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37
37-2
Measure limit speed of the

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

Vehicle system tester -V.A.S 5051 A,B,C Vehicle system tester -V.A.S 5052 Vehicle system tester -V.A.G 1551 Vehicle system tester -V.A.G 1552-
Test sequence
Connect vehicle system tester -V.A.G oder V.A.S-.

Leave the engine on and select the gearbox control
unit with Address word 02 Chap. 01-3.
Select function 08 read measured value block and

display group number 001.
Securely lock the vehicle with the hand and foot

brake.
Place selector lever in selector lever position D

Briefly apply full throttle (max. 5 s), if necessary repeat
test after 20 s. While doing so the speed listed in the
table must be reached.
If the final speed is not reached, the following faults

may be present:
Speed too high:
Forward clutch slips, overrunning clutch slips
Speed too low by up to

200 rpm:
Check engine setting
Speed too low by above

200 rpm:
Torque converter defective
In case of doubt always first check the engine setting and

if necessary correct.
The correct torque converter must always be assigned to
the gearbox.
Limit speed of the hydraulic converter
Gearbox identification characters Automatic Gearbox 001
ESK
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Torque converter identification char- Limit speed of the hydraulic conacters

verter
rpm
ACN
Measure limit speed of the hydraulic converter
23202620
37-2 page 1
37
37-2 page 2
Measure limit speed of the hydraulic converter
Edition 04.05
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37
37-3
Fault finding
This fault finding table lists faults and their possible causes.
Before fault finding

Perform the following tasks before fault finding:
1 - Perform self-diagnosis, this includes:
Compare control unit identification

Interrogating fault memory
eliminating electric/electronic faults
2 - Always check the ATF level

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

force and shifting comfort of the gearbox: Measuring the fixed brake speed
Chap. 37-2
Please note that these measurements will cause the ATF
temperature to rise sharply, therefore always check the
ATF level beforehand (!).
4 - Check whether the vehicle engine or other vehicle systems work perfectly, as disturbances to
these systems may also influence the automatic
gearbox.
If the automatic gearbox does not shift smoothly once
these tasks have been carried out, proceed with fault
finding according to this fault program.
Safety measures
Note
Comply with the safety instructions for test drives
Chap. 01-1.
Inspecting the shift elements (clutch/brake)

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

This allows to determine which shift elements do not work
correctly.
To accurately determine the defective shift element drive
and shift through each gear with the vehicle system tester
connected. To this end shift the selector lever from position 1 to D Chap. 01-5.
Before disassembling the gearbox and replacing the
clutch or brake, always check the wiring to the electronic
components of the relevant shift elements according to
the Current Flow Diagram. Pay special attention to plug
connections on the gearbox and control unit. Faults in the
vehicle wiring that are not eliminated may result in wrong
diagnoses and hence result in incorrect repairs. The solenoid valves on the slide valve body can also be checked
while driving Chap. 01-5.
If the plates of a shift element are burnt always disassemble and clean the gearbox (dirt in ATF). Replace slide
valve body.
Fault finding table

No.
1
Complaint
Vehicle does not move
forwards or backwards

Multi-function switch -F125- defective
Rectifying fault
Analysing measured value block 004

Chap. 01-5
Inspecting multi-function switch

Contact in switch damaged
-F125-.
Wiring/plug connection to switch
damaged/not connected accord- Performing electrical test, test step 2
Chap. 01-7.
ing to the Current Flow Diagram
Wiring and insulation defective
Replace wiring and plug connections
Plug in slide valve body broken
Replacing slide valve body Chap.
Current Flow Diagrams, Electrical

37-10.
Selector lever control cable loose at

one of its supports:
Replace shaft retainer
Shaft retainer (circlip) defective/not

clipped
or
Replacing and adjusting selector lever

control cable Chap. 37-5.
2
3
The driver panel is torn because the

dowel sleeves in the engine/gearbox flange are missing
Replace the engine/gearbox dowel
Vehicle does not move

forwards
1. 1st through 3rd gear clutch -K1defective
1. Repair 1st through 3rd gear clutch -
Vehicle does not reverse
Reverse gear-brake -B1- defective
Repairing reverse gear-brake -B1-
sleeves and driver panel.
K1- Chap. 38-3.

Chap. 38-6.
Reverse gear clutch -K2- defective
Repairing reverse gear-clutch -K2 Chap. 38-4.
37-3 page 2
Fault finding
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37

No.
4
Complaint
Gearbox oily
Rectifying fault
Seals or components outside gearbox leak
Clean the engine/gearbox and locate
Gearbox leaking
where the gearbox or engine leaks if

necessary use leak-oil search spray
spare part No. G 001 900 A1.
Seal or replace defective components

on a leaking gearbox.
Replace gasket rings, gaskets,

screwed connections or gearbox
housing (converter housing).
Seal engine
ATF level too high, ATF expelled by Clean gearbox, check ATF level if necEngine leaks
essary drain off Chap. 37-8.
fresh air system

5
ATF escapes around the

torque converter
Distance dimension of the driver

panel N.O.K.
Adjust the distance dimension of the
Gasket ring for torque converter defective
Replacing the gasket ring for torque
Bush in torque converter defective/

loose
driver panel Engine Mechanics;

Rep. Gr. 13.
converter; if the contact surface on the

torque converter is damaged also replace the torque converter Chap.
32-1.
Disassemble and assemble ATF
ATF pump leaks
pump and replace defective components Chap. 38-1.
Inspect converter for damage (visual

inspection).
6
Visible soiling of the ATF

and/or engine coolant
ATF-radiator defective, this causes

the coolant and ATF level to drop
Precondition: no engine oil in the coolant (cylinder head seal etc. O.K.)
Replace ATF-radiator
Replace the coolant and ATF.
The coolant may damage plates and
seals in the gearbox. After replacing the
coolant and the ATF:
Perform a test drive and inspect the

solenoid valve and position of the
shift elements Chap. 01-5.
Inspect shifting points Chap. 37-1.

Measure fixed brake speed Chap.
37-2.
If there are functional problems repair the
gearbox Chap. 37-9.
7
Gearshift mechanism is
stiff
Gearshift mechanism is stiff outside

the gearbox
Remove selector lever control cable

from the lever/gearshift shaft.
Repairing the gearshift mechanism

Chap. 37-4.
Always replace a buckled selector lever control cable Chap. 37-5.
Gearshift mechanism in gearbox

stiff
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Fault finding
Disassembling and assembling parking position Chap. 38-9.
37-3 page 3
37
No.
Complaint
Rectifying fault
Not all selector lever positions can be engaged, engaged driving positions
are not operational

its support:

clipped
or

Parking position does not

catch
Selector lever control cable defective or incorrectly set

its support:

clipped
or
Replacing selector lever control cable

Chap. 37-5.
10
11
Locking lever, parking gear or locking lever activation defective
Repairing locking lever, parking gear
Parking position jerks

out of catch (selector lever
occasionaly stiff from P
to R)
Ferraria effect of the locking lever

for parking gear if:
Apply handbrake before engaging
Noises in the final drive
Tapered-roller bearing loud
or locking lever activation Chap.

38-9.
parking position.
Vehicle parked on a hill or the parking position catch is put under tension because of repeated
gearshifting.
Replacing tapered-roller bearing

Chap. 39-2.
Replacing input shaft Chap. 39-2.

Replacing drive gear with output gear
Input shaft loud

Drive gear loud
Output gear loud
Drive train (input shaft with differential ring gear) loud
12
13
Chap. 39-2.
Driveability: jerking during Throttle valve supports leak

idling or jerking during certain engine/gearbox motions
Inspect throttle valve supports and air
Engine speed drops when

a driving position is engaged
Parking/Neutral (P/N) signal is not

recognised by the engine control
unit
Testing data BUS Electrical system;
4AV control unit defective
Perform self-diagnosis of the engine
deflector for tightness Engine, Fuel

Injection; Rep. Gr. 24.
Rep. Gr. 90.
control unit Engine, Fuel Injection;

Rep. Gr. 01.
37-3 page 4
Fault finding
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37

No.
14
Complaint
Vehicle does not start or
also starts in R-D-3-2-1

Wiring of the multi-function switch
-F125- or of the starter inhibitor relay -J207- defective
Rectifying fault
Check wiring according to current flow
diagram Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Testing data BUS Electrical System; Rep. Gr. 90.
15
Vehicle voltage control unit -J519defective
Inspecting vehicle voltage control unit
Inspect and if necessary replace multi-
Starter inhibitor relay -J207- defective
Replacing starter inhibitor relay -J207-
Selector lever can be shift- Selector lever lock solenoid -N110ed out of N or P without defective
pressing the brake.
-J519- Electrical System;

Rep. Gr. 90.
function switch -F125- Chap. 01-7.

Chap. 01-2.

Chap. 01-5.
Inspecting selector lever lock solenoid

-N110- Chap. 01-7.
Vehicle voltage control unit -J519defective
Inspecting vehicle voltage control unit
Wiring for selector lever lock solenoid -N110- interrupted
Check wiring according to current flow
no signal from brake light switch -F-
-J519- Electrical System;

Rep. Gr. 90.
diagram Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Chap. 01-5.
Inspecting and if necessary replacing

brake light switch -F- Running
Gear; Rep. Gr. 45.
Data BUS defective

Rep. Gr. 90.
Read-out on display of
-V.A.G 1552-: no fault detected!
Select control unit from spare part catalogue and replace Chap. 01-2.
Automatic gearbox control unit

-J217- defective
16
Selector lever cannot be

shifted out of N or P
even though the brake is
pressed.
Brake light switch -F- defective/no

signal
Inspecting and if necessary replacing
Data BUS defective
brake light switch -F- Running

Gear; Rep. Gr. 45..
Rep. Gr. 90.
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Fault finding
37-3 page 5
37
No.
Complaint
17
Shifting does not occur (or

only sporadically)

Plug of the vehicle speed sender
-G68- and gearbox speed sender
-G38- interchanged
Rectifying fault
Re-connect plug
Perform a test drive
Perform self-diagnosis Chap. 01-3.
Multi-function switch -F125- Chap.
01-7.
Check and if necessary repair wiring

Contacts in switch damaged
according to current flow diagram
Wiring/plug connection to switch
damaged/not connected according to the Current Flow Diagram
Wiring and insulation defective
Replace wiring and plug connections
Replace slide valve body.

Replacing slide valve body, ATF and
Piston slide valve or solenoid valve

in slide valve body stuck

ATF strainer Chap. 37-8.
Perform test drive with -V.A.G 1552and check whether all solenoid valves
and shift elements are activated while
driving Chap. 01-6.
18
When shifting gears all

gearshifts stiff/jerky
Pulse gear for vehicle speed sender

-G68- loose/broken
Replacing drive gear Chap. 39-2.
Plug of the vehicle speed sender

-G68- and gearbox speed sender
-G38- interchanged. When interrogating the fault memory in this instance the gearbox speed sender
-G38- displays implausible signal.
perform self-diagnosis with the engine

off, erase fault memory, initiate basic
setting Chap. 01-4.
Re-connect plug
Again perform self-diagnosis Chap.
01-3.
no signal from gearbox oil temperature sender -G93-/sender defective

Chap. 01-5.
Performing electrical test, test step 11

Chap. 01-7.
Replace gearbox oil temperature

sender -G93-.
Short-circuit between the valve
wires
Inspecting/replacing valve wires
Incorrect control unit fitted/control

unit defective
Read out control unit identification
Chap. 01-7.
Chap. 01-3.
Select control unit from spare part catalogue, compare and if necessary replace Chap. 01-2
Piston slide valve in slide valve
body or solenoid valve defective
37-3 page 6
Fault finding

38-8
Edition 07.00
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37

No.
19
Complaint
when shifting gears one
gearshift is stiff/jerky

one shift element (a clutch or a
brake) defective
Rectifying fault
Check in which gearshift the gear is hard:
Connect vehicle system tester -V.A.G

1552-; read measured value block
Chap. 01-3
Perform a test drive. The table solenoid valves and position of the shift elements in the Workshop Manual
indicates which shift elements are affected Chap. 01-5.
replacing the affected shift elements

Chap. 37-9.
20
Gearshifts too drawn out a clutch or a brake is defective
Check in which gearshift the faulty gear

occurs:
Connect vehicle system tester

-V.A.G 1552-; read measured value
block Chap. 01-3.
Perform a test drive. The table solenoid valves and position of the shift elements in the Workshop Manual
indicates which shift elements are affected Chap. 01-5.
Torque converter defective
Measure fixed brake speed Chap.

37-2.
21
Stiff gearshift immediately

after repairs
Piston slide valve is slide valve

body stuck
Read-out on display
Initiating basic setting Chap. 01-4
38-8
-V.A.G 1552- no fault detected!
Damage to the wiring excluded

(plug connections !)
Basic setting not initiated
22
Gearbox shifts down at

constant speed without
visible reason
ATF is insufficiently cooled, by shifting down the gearbox performs a

safety function.
Check why the ATF temperature rises
Engine speed signal is not detected

by the automatic gearbox control
unit
unacceptably. Check out additional installations or modifications to the vehicle that are likely to affect the cooling.
Also the subsequent installation of a
trailer coupling device without corresponding modificaton of the fan motor
may result in cooling problems.
Chap. 01-5.
Perform self-diagnosis of the engine
control unit Engine, Fuel Injection;

Rep. Gr. 01.

Rep. Gr. 90.
23
Gearbox does not shift

during kickdown
Accelerator pedal position sender

-G79- defective/no signal
Inspecting accelerator pedal position

sender -G79- Engine, Fuel Injection; Rep. Gr. 24.
Initiating basic setting Chap. 01-4.

Rep. Gr. 90.
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Fault finding
37-3 page 7
37
No.
24

Complaint
Gearbox only shifts as
heating increases

Piston slide valve in slide valve
body or solenoid valve defective
Rectifying fault

38-8.
Given an ATF temperature below

15 C the gearbox does not shift
into 4th gear. No fault.
25
Gearbox shifts into emergency running mode
Read-out on display of -V.A.G 1552gearbox speed sender -G38- implausible signal plug connection of
the gearbox speed sender -G38and vehicle speed sender -G68- interchanged
Plug connection at gearbox damaged/loose contact
Soiling or corrosion of contacts

Plug contacts in plug housing
perform self-diagnosis with the engine

off, erase fault memory, initiate basic
setting Chap. 01-4.
Re-connect plug
Perform self-diagnosis again
Inspect wiring and plug connections
according to the Current Flow Diagram and repair if necessary
damaged (not fully inserted)
Short-circuit/interruption in wiring
loom
Short-circuit/interruption between
the valve wires or wires to the solenoid valves
Perform self-diagnosis and electrical
test, subsequently replace wiring or

components Chap. 01-3.
38-8.
Piston slide valve is slide valve

body stuck
Read-out on display of
Read out control unit identification
-V.A.G 1552-: no fault detected!
26
Selector lever position 1

automatic gearbox does
not shift into 1st gear (no
power transmission in 1st
gear)
Chap. 01-3.
Select control unit from spare part cat-
Incorrect control unit fitted/control

unit defective
alogue and replace if necessary
1. 1st through 3rd gear-clutch -K1or reverse gear-brake -B1- defective
Observe the safety measures and

notes: Inspecting the solenoid valves
and shift elements while driving
Chap. 01-6.
Repairing reverse gear-brake -B1 Chap. 38-6.
1. Repairing 1st through 3rd gearclutch -K1- Chap. 38-3.
Repairing the overrunning clutch

Chap. 38-2.
27
Selector lever position D,

3 or 2 automatic gearbox
does not shift into 1st gear
(no power transmission)
1. 1st through 3rd gear clutch -K1or overrunning clutch defective

Chap. 01-6.
1. Repairing 1st through 3rd gearclutch -K1- Chap. 38-3.

Chap. 38-2.
37-3 page 8
Fault finding
Edition 07.00
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37

No.
Complaint
28
Selector lever position D,

3 or 2 automatic gearbox
does not shift into 2nd
gear
2. 2nd and 4th gear-brake -B2- defective
Rectifying fault

Chap. 01-5.
2. Repairing 2nd through 4th gearbrake -B2- Chap. 38-7.

Chap. 38-2.
29
Selector lever position D

or 3 automatic gearbox
does not shift hydraulically
into 3rd gear (3H)
3. 3rd and 4th gear-clutch -K3- defective

Chap. 01-5.
3. Repairing 3rd through 4th gearclutch -K3- Chap. 38-5.
30
Selector lever position D Lockup clutch defective

or 3 automatic gearbox
does not shift mechanically into 3rd gear (3M)

Chap. 01-5.
Replacing torque converter Chap.

32-1.
31
Selector lever position D

not shift mechanically into
4th gear (4M)
Lockup clutch defective

Chap. 01-5.
Replacing torque converter Chap.

32-1.
32
Selector lever position R

not shift into reverse gear
Reverse gear-clutch -K2- defective

reverse gear-brake -B1- defective

Chap. 01-5.
Repairing reverse gear-clutch -K2 Chap. 38-4
Repairing reverse gear-brake -B1 Chap. 38-6.
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Fault finding
37-3 page 9
37
37-3 page 10
Fault finding
Edition 07.00
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37
37-4
Inspecting gearshift
mechanism
Inspecting gearshift mechanism

Note
In selector lever positions 1, 2, 3, D and R it
must not be possible to activate the starter.

At speeds above 5 km/h and shifting in selector lever
position N the selector lever lock solenoid must not

engage and block the selector lever. Selector lever
can be shifted in a driving position.
At speeds below 5 km/h (virtual standstill) and shifting
in selector lever position N the selector lever lock solenoid must only engage after approx. 1 s. The selector lever can only be moved from position N by
activating the brake pedal.
Selector lever in position P or N and ignition

switched on:
Brake pedal is not actuated:

The selector lever is locked and cannot be shifted
from position P or from N. The selector lever lock
solenoid blocks the selector lever.
Brake pedal is actuated:

The selector lever lock solenoid releases the selector
lever. It is possible to engage a driving position. Slowly shift selector lever from P through R, N, D, 3, 2,
1; while doing so check whether the selector lever position in the dash panel insert corresponds with the actual selector lever position.
Inspecting and adjusting the selector lever control cable

Inspection
Shift selector lever to position P.

Remove noise insulation 1.4/55, 1.4/74 Engine Mechanics; Rep. Gr. 10.
Lever off upwards selector lever control cable -A- from

lever/gearshift shaft -B- with open-end wrench and lay
aside in such a way that the extremity can move freely.
1 - Open-end wrench size 13, commercially available
Do not bend or buckle selector lever control cable.
Shift selector lever from P to 1.

S37-0103
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37-4 page 1
37
Gearshift mechanism and selector lever control cable

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

damage, if necessary replace control cable.
Use pliers to press selector lever control cable onto

the lever/gearshift shaft.
Setting

Release screw -A- at the front ball socket of the selector lever control cable -B-.
Place lever/gearshift shaft at gearbox in P. Locking
lever must engage in parking gear, both front wheels

are blocked (cannot be simultaneously turned in one
direction).
Tighten screw -A- (8 Nm).

Inspect gearshift mechanism 37-4 page 1.
S37-0105
37-4 page 2
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37
37-5
Removing and Installing

Shift Mechanism
Removing and Installing Shift Mechanism

Note
After installing, check gearshift mechanism Chap. 374.
Removing
P
N
D
First check whether a coded radio set has been installed. If this is the case obtain the anti-theft code.

Disconnect the earth strap from the battery with the ignition off.
Remove grip of selector lever 37-5 page 5.

Removing the centre console Body Work;
Rep. Gr. 68.
S37-0104
Remove surround -arrows- with cover and selector lever position indicator by pulling it upwards from the
gearshift mechanism.
Disconnect the plug connection -arrow- of the selector

lever position indicator.
S37-0107
Disconnect the plug connector -arrow- for selector lever lock solenoid -N110-.
S37-0108
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37
Detach bracket -1- below the exhaust system.

Unclip the Lambda probe line from holder -2-.
Remove protective cover -3- and disconnect the plug
connection.
Separate exhaust system at the double clamp -4-.

Remove exhaust pipe with catalyst 1.4/55, 1.4/74
Engine - Mechanics; Rep. Gr. 26.
Unbolt bracket -5- for exhaust system.

Remove heat shield -6-.
Unscrew cover at bottom from the shift housing.

Use a screwdriver to press off the selector lever control cable -3- from the selector lever -2-.
Remove the retaining clip -1- for the selector lever

control cable.
3
A37-0213
37-5 page 2
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37
Unscrew nuts -arrows- attaching the shift housing.

While doing do not allow the shift housing to fall.
Pull shift housing from selector lever control cable and

lower.
P
N
D
Installing

When installing replace the seal between the selector
lever control cable and the shift housing and the seal
between the cover and the shift housing.
Tightening torques:
S37-0106
Shift housing to body
25 Nm
Strut to body
25 Nm
Removing and installing the selector lever control cable
Note
Adjusting the selector lever control cable Chap. 37-
4.
Inspecting the gearshift mechanism Chap. 37-4.
Removing
S37-0109
Pull off the retaining clip -1- for the selector lever control cable at the support -2-.
Unhook selector lever control cable from the holders

-arrows-.
S37--0110
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37
Lever off selector lever control cable -A- from the lever/gearshift shaft -B- using open-end wrench.
B
1
S37-0103
Detach bracket -1- below the exhaust system.

Unclip the Lambda probe line from holder -2-.
Remove protective cover -3- and disconnect the plug
connection.
Separate exhaust system at the double clamp -4-.

Unbolt bracket -5- for exhaust system.

Remove heat shield -6-.
Unscrew cover at bottom of gearshift mechanism.
37-5 page 4
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37
Use a screwdriver to press off the selector lever control cable -3- from the selector lever -2-.
Remove the retaining clip -1- for the selector lever

control cable.
Remove selector lever control cable.

Carefully pull the selector lever control cable out of the
engine compartment.
Installing

Note
Inspect boot for damage; the boot must be replaced
together with the selector lever control cable.

Check correct fitting of the boot and do not install the
boot twisted.
Do not bend or buckle selector lever control cable.
Selector lever and lever/gearshift shaft are in position

P, the front wheels are blocked.
A37-0213
When installing replace the seal between the selector

lever control cable and the shift housing and the seal
between the cover and the shift housing.
D
3
Removing and installing the selector lever grip
2
1
Removing
Shift selector lever to position 2.

Push sleeve -1- down.
Pull off grip -2- from selector lever.
S37-0111
Installing
Push the grip -2- onto the selector lever up to the stop.
D
3
Fitting position:
Button points towards driver.

1
Slide the sleeve -1- upwards while turning until the two
wide pegs of the grip -A- catch in the slots of sleeve
-B- and the sleeve and grip are felt to click in position.
1
B
A
2
S37-0112
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37
37-5 page 6
Edition 07.00
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37
37-6
Disassembling and assembling the gearshift mechanism
Note
Grease bearing and friction surfaces with polycarbamide grease -G 052 142 A2- SP No.
1 - Grip for selector lever
T removing and installing
1
Chap. 37-5
2 - Sleeve
2
27
13
T catches in the selector lever
28
grip
14
3
T blocks the pulling off of the
29
selector lever grip
15
3 - Cover
30
4
T with selection range
31
4 - Cover strip
16
T insert in surround item 7
6
5 - Selector lever position indicator
32
17
T Clip printed circuit board for
33
5
18
selector lever position and in34
6
dicator (lighting) off or on
35
T The contacts for selector le36
7
19
ver position point towards the
contact spring item 27 of
37
38
the selector lever
20
T Secure plug housing with
8
holder item 6 to surround
9
39
item 7
21
T Hook fiberoptic cable and ca22
ble to plug housing onto its
10
supports on the surround.
23
11
T Disconnect and connect plug
40
41
24
connection 37-6 page 3
12
6 - Bracket
25
T for wiring loom
42
26
S37-0100
7 - Surround
T to remove pull off upwards
with selector lever position indicator item 5 and cover item 3
8 - 7 Nm
9 - Washer
10 - Locking segment
11 - Bracket
12 - Latch spring with roller
T catches in the slots of the selector lever item 13
T adjust 37-6 page 3
13 - Selector lever
T with tension rod, pressure spring, slots, contact spring for selector lever position and release for interlock cable
T removing and installing Chap. 37-5
14 - Roller
15 - Circlip
16 - Gasket
T with studs press into the supports of the gearshift bracket item 17
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37-6 page 1
37
17 - Gearshift bracket
T need not be removed to replace the selector lever control cable or the component parts of the gearshift mechanism
18 - Collar screw
T with serration
T only counterhold screw head, do not turn!
T grease at shank
19 - Locking lever
T to lock in selector lever position P
20 - Washer
21 - 2.5 Nm
22 - Gasket
T always replace
23 - 8 Nm
T 2 pieces
24 - Bottom cover
T for gearshift bracket
25 - 1.5 Nm
T 14 pieces
26 - Gasket
T always replace
27 - Contact spring
28 - Contact plate
29 - 4 Nm
T to release and tighten put selector lever in P
30 - 1.3 Nm
T 2 pieces
T Solenoid on gearshift bracket
31 - Selector lever lock solenoid -N110T removing and installing 37-6 page 3
T remove and install in selector lever position 1 only
T Move wiring loom in such a way that it can neither be damaged by the selector lever nor by the selector lever
lock solenoid
T when removing pay attention to the spring and locking bolt
T install together with the locking bolt and spring, while doing so move the selector lever up and down a little
T can be checked in the electrical test and in the measured value block Rep. Gr. 01
32 - Pressure spring
33 - Locking bolt
34 - 13 Nm
T always replace
35 - Washer
36 - 25 Nm
T with collar
T 4 pieces
37 - Gasket
T always replace
38 - Retaining clip
T always replace
T for selector lever control cable on gearshift bracket
T install the angled end towards the inside of the gearshift bracket
39 - Selector lever control cable
T do not bend or buckle
T if the boot is damaged the selector lever control cable must be replaced
37-6 page 2
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37

T inspecting and setting Chap. 37-4
T do not grease the ball sockets at the cable extremities
40 - 8 Nm
T for selector lever control cable
41 - Retaining clip
T for selector lever control cable on gearbox
T always replace
T angled end point towards the end of the selector lever control cable
42 - 25 Nm
T 2 pieces
T for support to gearbox
Adjusting latch spring with roller

Adjusting requirements:
Grip for selector lever removed

Cover of gearshift mechanism removed
Centre console removed
Release screw -1 -.
Press latch spring with roller in the direction of the ar-
row in the slots of the selector lever -2-.

While doing so tighten screw -1-.
Removing and installing selector lever

lock solenoid -N110Removing
First check whether a coded radio set has been installed. If this is the case obtain the anti-theft code.
S37-0124

Removing selector lever grip Chap. 37-5.

Removing the centre console Body Work;
Rep. Gr. 68.
P
N
D
Remove surround -arrows- with cover and selector lever position indicator by pulling it upwards from the
gearshift mechanism.
S37-0104
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37
Disconnect the plug connection -arrow- of the selector

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

lock solenoid -N110-.
Lever off holder of wiring loom -2- from gearshift

bracket.
Cut through cable straps -3-.
S37-0113
Remove surround from gearshift bracket -arrows 1-.

The rear screw is not visible in the figure.
Release screws -arrows 2- from the solenoid.

2
2
S37-0114
37-6 page 4
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37
Pull out the solenoid -1-, the spring -2- and the locking
bolt -3-.
Installing
The installation occurs in reverse order, while paying attention to the following:
To install the solenoid the selector lever must be in po-
sition 1.
1
S37-0119
Insert the solenoid with spring and locking bolt in the

gearshift bracket.
The locking bolt must catch into the support -arrow- of

the gearshift bracket.
Slightly move the selector lever while doing so.
S37-0120
After installation the locking bolt -1- must be located at

the front side of the gearshift bracket -2-.
Inspecting the gearshift mechanism Chap. 37-4.
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S37-0121
37-6 page 5
37
37-6 page 6
Edition 07.00
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37
37-7
Removing and installing

the gearbox
Removing
Gearbox mount -3282 Adjusting plate -3282/24 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Engine/gearbox jack, e.g. -V.A.G 1383 A Gearbox attachment device -MP 3-478 Hose clamps -MP 7-602-
Supporting device -MP 9-200-
Remove the engine trim panel.

Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
Remove battery and battery tray Electrical System;
Rep. Gr. 27.
S37-0109
Pull off the retaining clip -1- for the selector lever control cable at the support -2-.
Lever off selector lever control cable -A- from the lever/gearshift shaft -B- using open-end wrench.
B
1
S37-0103
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37
Clamp off the two ATF-radiator hoses with hose

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

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

Remove holder -2- from the gearbox -arrows-.
S37-0069
37-7 page 2
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37
Pull out cable duct -1- from the lifting eye for the gearbox -2- in the -direction of the arrow-.
1
2
S37-0070
Pull off cable duct -1- from the engine/gearbox connecting screw -2- in the -direction of the arrow-.
Remove engine/gearbox connecting screws at the

top.
Remove securing screw for starter at the top.
S37-0071
Pull off and disconnect the plug connection -1- from

the bracket -2- on the suspension strut dome in the
-direction of the arrow-.
Remove front left wheel and raise vehicle.

Remove the front left wheelhouse liner Body Work;
Rep. Gr. 66; Wheelhouse liner.
Remove left drive shaft Running gear; Rep. Gr. 40.

Remove right drive shaft from the flange shaft and tie
up as far as possible. Avoid damaging the paintwork
on the drive shaft during this operation.
S37-0072
Removing starter Electrical System; Rep. Gr. 27.
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37
Unplug connector -arrow- from speedometer sender

-G22-.
Remove converter cover plate.
S37-0074
Release nut -arrow- from the torque converter (3 pieces).
Unscrew the engine/gearbox connecting screw above

the right flange shaft.
N37-0556
Unbolt pendulum support -1- -arrow A-.

Remove cover plate -2- from the gearbox -arrow B-.
Remove protection plate for ATF-pan.
B
1
A
A
37-7 page 4
S37-0075
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37
Install supporting device -MP 9-200-.

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

spindles.
Unscrew the fixing screws -arrows- from the gearbox

mount.
Release screws for gearbox mounting bracket.
S37-0076
Remove screws -2- for engine mounting.

Lower engine/gearbox unit approx. 60 mm and re-
move gearbox mounting bracket.

Note
When lowering the engine/gearbox unit, make sure the
gearbox does not touch the assembly carrier.
3
S10-0140
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37
Insert engine mount -3282- into engine/gearbox jack,
3282/24
e.g.-V.A.G 1383 A-.
Align the engine/gearbox jack with gearbox mount

-3282-, adjusting plate -3282/24- for 001 gearbox
and the support elements (adjusting plate only fits in
one position).
3282
Align arms of the gearbox mount to match the holes in

the adjusting plate.
Screw in the mounting elements as shown on adjusting plate.
Position engine/gearbox jack below vehicle, arrow

symbol on adjusting plate points in the direction of
travel/vehicle.
N37-0559
V.A.G 1383A
Align adjusting plate parallel to the gearbox and lock
securing mount -arrow- at gearbox.
3282/24
3282
S37-0077
Unbolt heat shield -1- from the gearbox -arrow A-.

Release screw for engine/gearbox fixation -arrow B-.
Push gearbox off engine, simultaneously press off the
torque converter from the driver disc.
Push torque converter against the ATF-pump.
Ask a second mechanic to push the engine forwards.
After this lower gearbox carefully.
Secure converter against dropping out.
S37-0073
37-7 page 6
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37
Bolt the gearbox suspension device -MP 3-478- to the

flange of the gearbox housing.
MP 3-478
Adjust supporting arm at slide with locking pin -arrow-.

Number of visible holes = 5.
Raise gearbox with workshop crane and gearbox suspension device -MP 3-478-.
Place down gearbox, e.g. in a transport container.
Installing
The installation of the gearbox occurs in reverse order,
while paying attention to the following:
S37-0122
Install engine/gearbox mounting free of stress 1.4/

55; 1.4/74 Engine, Mechanics; Rep. Gr. 10.
Check adjustment of the selector lever control cable,

if necessary adjust Chap. 37-4.
Checking ATF level and topping up Chap. 37-8.

Note
Check whether the dowel sleeves for centering the
engine/gearbox are present in the cylinder block; insert if necessary.

Installing starter/cable Electrical System;
Rep. Gr. 27.

Check the vehicle equipment when the battery is re-
connected. Encode the radio, re-set the clock, initialise the power windows Inspection and
Maintenance.
Tightening torques
Gearbox on engine.
1)
2)
Pos.
Screw
Pieces
Nm
M12 x 65
80
M12 x 75
45
M7 x 12
15
M12 x 70
80
51)
M8 x 30
25
M8 x 35
25
72)
M8 x 35
25
6
5
4
A
Screw with threaded pin M8

Screw with T-pin
A
2
3
3
S37-0118
A: Dowel sleeves for centering
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37
Pendulum support
Note
Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier.
Mounting sequence:
Tighten screws -1- and -2- by hand.

Ensure maximum distance between gearbox and as-
sembly carrier and tighten screws -1- to tightening

torque.
Then tighten screw -2- to tightening torque.
S10-0133
1 - 30 Nm + 90 (1/4 turn) - replace

2 - 40 Nm + 90 (1/4 turn) - replace
Components
Torque
Converter to driver disc
85 Nm
Protection plate for ATF-pan to

gearbox
45 Nm
Selector lever control cable support to gearbox
25 Nm
Left gearbox mounting bracket to

gearbox M81)
20 Nm + 90
Gearbox mounting bracket to gearbox mount M10 1)
40 Nm + 90
Tighten drive shaft to flange shaft

diagonally across in 2 steps (I and
II) to M81)
I - 10 Nm
II - 40 Nm
Plate nut of drive shaft to wheelbearing housing
50 Nm
Steering joint to track control arm

M81)
20 Nm + 90
Coupling rod to anti-roll bar
40 Nm
Wheel bolts to wheel hub
120 Nm
1)
Always replace these bolts.
37-7 page 8
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37
37-8
Checking and topping up

ATF level

Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Diagnostic cable -V.A.G 1551/3 Vehicle system tester -V.A.G 1552 ATF filling system -V.A.G 1924-
If ATF is added, use ATF with Spare Part No.

-G 052 990 A2-.
The gasket ring -arrow- for the screw plug for ATF in-
N38-0037
spection must always be replaced.
Inspecting ATF level
V.A.G 1924
Test conditions
Gearbox not in emergency running mode, ATF temperature not above 30C.
Vehicle on level ground

Selector lever in P
Inspection
Attach the reservoir of the ATF filling system

-V.A.G 1924- to the vehicle.
Connect vehicle system tester -V.A.G 1552- with the

diagnostic cable -V.A.G 1551/3- Chap. 01-3.
Enter address word 02 gearbox electronics and

move forward until select function XX appears in the
display.
Start engine.
Raise vehicle.
Position the catch pan under the gearbox.
Press
Vehicle system test

Select function XX
0 and 8 for the function reading measured
value block and confirm the entry with Q .
Press
V.A.G 1552
S37-0078
HELP

0 , 0 and 2 for the function display group
number 002 and confirm the entry with Q .

0%
4%
30C
->
12.9 V
The third display field indicates the ATF temperature.

Note
At the start of the inspection the ATF temperature must
not exceed 30 C.
Edition 07.00
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Checking and topping up ATF level
37-8 page 1
37
Bring ATF to test temperature.

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

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

This completes the ATF inspection.
S37-0079
Topping up ATF
Lever off cap -arrow- securing the screw plug with a
screwdriver.
This destroys the cap catch, therefore always replace the
cap.
S37-0080
Pull screw plug from the filler tube.

Top up ATF with the ATF filling system -V.A.G 1924until ATF flows out of the inspection hole -arrow-.
Note
Too much or too little ATF filling impairs the gearbox function.
V.A.G. 1924
S37-0081
37-8 page 2
Edition 07.00
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37
Tighten screw plug with new gasket ring -arrow 1- to

15 Nm.
Insert screw plug of the filler tube and secure with new
cap -arrow 2-.
1
Replacing ATF
S37-0082

Remove screw plug for ATF inspection in the oil pan
-arrow-.
Unscrew the overflow tube through the inspection

hole.
Drain the ATF.

Install overflow tube.
Tighten the screw plug by hand.
If ATF is added, use ATF with Spare Part No.
-G 052 990 A2-.
Pour in approx. 2 litres of ATF through the filler tube.

Then start the engine and while the vehicle is standing
shift through all selector lever positions once.
S37-0079
Subsequently check ATF level and top up Chap.

37-8.
Edition 07.00
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37-8 page 3
37
37-8 page 4
Edition 07.00
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37
37-9
Disassembling and assembling the gearbox
Gearbox with shift elements

Arrangement of the shift elements
Before repairing the gearbox first perform self-diagnosis Rep. Gr. 01.
12345-
3. 3rd and 4th gear-clutch -K3Reverse gear-brake -B1Overrunning clutch

Reverse gear-clutch -K21. 1st through 3rd gear clutch
-K16 - 2. 2nd and 4th gear-brake -B27 - Lockup clutch integrated in
torque converter -LC-
N37-0612
Position of the shift elements

In the event of complaints about unsatisfactory acceleration and speed values or more generally for drive faults,
refer to the following table to determine which shift elements are activated in the individual gears. This allows to
determine which shift elements do not work correctly.
All gears are hydraulically shifted.
The 3rd and 4th forward gears are mechanically driven by
the torque converter lockup clutch at a specified load and
speed.
Edition 07.00
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37-9 page 1
37
Gear
B1
1H
(X)
2H
B2
K1
K2
K3
LC
X
X
X
3H
3M
4H
4M
X
X
X - closed clutches, brakes or overrunning clutch

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

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

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

pump up to large sun gear
37-10 page 2
II - Removing and installing cover for gearbox housing up to
the drive gear 37-10
page 3
II
S37-0084
Edition 07.00
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Disassembling and assembling planetary gear - Summary of

components
37-10 page 1
37
I - Removing and installing ATF pump up to large sun gear

Overview 37-10 page 1
1 - 20 Nm
2 - ATF pump
T disassembling and assem3
4 5 6 7
bling Chap. 38-1
1 2
3 - Gasket
T for ATF pump
4 - Brake band -B2T 2. 2nd and 4th gear-brake
T setting Chap. 37-12
T lay aside in fitting position
Chap. 37-11
T insert the piston pressure rod
15
item 19 and adjusting
screw item 19 in the
moulded part of the brake
band
5 - 45 Nm
6 - Adjusting screw
T for brake band -B2T always replace
14
T setting brake band Chap.
13
12
37-12
11
7 - Adjusting washer
T Determining thickness
21
Chap. 37-12, setting
clutch clearance between 20
K2- and ATF pump
19
8 - Reverse gear-clutch -K2T disassembling and assembling Chap. 38-4
9 - Axial needle bearing
T check fitting position
37-10 page 4
10 - 1. 1st through 3rd gear clutch -K1- with turbine shaft
T disassembling and assembling Chap. 38-3
T check fitting position 37-10 page 4
12 - Drive shaft
13 - Axial needle bearing with washer
T check fitting position 37-10 page 4
14 - Sun gear, large
15 - Drive pinion
T assigned to gearbox identification characters as a spare part
16 - Gearbox housing
17 - Circlip
18 - Cover
T with 4th gear control piston
19 - Control piston 2nd and 4th gear brake
T for brake band -B2-
37-10 page 2
10
16
18

components
17
N37-0614
Edition 07.00
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37

20 - Spring
21 - Spring
II - Removing and installing cover for gearbox housing up to the drive gear
Overview 37-10 page 1
1 - 20 Nm
2 - Cover for gearbox housing
T with piston and spring support plate for reverse gearbrake -B1T disassembling and assembling Chap. 38-6
T check fitting position
37-10 page 4
4 - Circlip
5 - Disc spring
T Check fitting position: large
diameters face one another
6 - Pressure plate -B17 - Outer plate -B1T Piece number outer plates B1- Chap. 00-3
8 - Inner plate -B1T Piece number inner plates B1- Chap. 00-3
15
T lay in ATF for 15 minutes be14
fore installing
9 - Pressure plate -B110 - 3. 3rd and 4th gear-clutch -K3T disassembling and assembling Chap. 38-5
check fitting position 37-10
page 4
12 - Planet carrier
T when inserting in overrunning clutch turn to the left
13 - Circlip
T for overrunning clutch
14 - Thrust washer
T for overrunning clutch item 15
15 - Overrunning clutch
16 - Tensioning screw, 60 Nm
T secures the drive gear
17 - Lock washer
T for tensioning screw
T always replace
Edition 07.00
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17
18
16
22
21
19
20
8
14
13
12
11
10
7
1
5
7

components
2
S37-0085
37-10 page 3
37
18 19 20 -
21 -
22 -

T insert the 4 pegs of the lock washer in the holes of the gearbox housing
Drive gear with ring gear
T Removing and installing ring gear Fig. 1 in 37-10 page 4
Ring gear
Circlip
T for ring gear
T removing and installing Fig. 1 in 37-10 page 4
Input gear
T with grooved ball bearing
T Grooved ball bearings cannot be removed from the drive gear
Gearbox housing
Fig. 1:
Removing and installing the ring gear from

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

the drive gear -C-.
Installing:
Insert the circlip -A- in the circular slot of the drive

gear.
Compress the circlip and insert ring gear in the serration of the drive gear up to the stop.
After releasing the circlip the ring gear must be locked.
S37-0101
Fitting position of the adjusting washer -F- and

axial needle bearing in the planetary gear
Dimensions of the adjusting washer and of the axial needle bearing
Bearings
Inside mm
Outside mm
22,10
40,00
30,00
45,00
29,00
48,00
18,35
34,50
32 to 34
49,50
35,30
70,00
S37-0123
37-10 page 4

components
Edition 07.00
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37
37-11 Disassembling and assembling planetary gear Assembly sequence

Engine and gearbox mount -MP 1-202 Gearbox attachment device -MP 3-478 Key -T10003 Assembly stand -MP 9-101 Catch pan
Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Sealant -D 176 404 A2-
Disassembling planetary gear

Gearbox suspended on gearbox suspension device
-MP 3-478-
N37-0562
Remove screw plug -1-.

Remove screw plug -2- and ATF overflow tube -3-.
Drain the ATF.
Remove torque converter.
Release nut -arrow A- for lever/gearshift shaft.
Remove screws -arrows B- for multi-function switch
from the gearbox.
Removing electrical connections and sender from
gearbox Chap. 01-2.
B
S37-0086
B
Secure gearbox to engine and gearbox mount -MP
1-202- -arrows- and place in assembly stand
-MP 9-101-.
Remove gearbox suspension device -MP 3-478-.
MP 9-101
MP 1-202
Edition 07.00
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Disassembling and assembling planetary gear - Assembly

sequence
S37-0087
37-11 page 1
37
Remove ATF radiator from gearbox -arrow-.
MP 9-101
MP 1-202
S37-0088
Remove oil pan -arrow-.
S37-0115
Unclip sender -1- for ATF temperature.

Disconnect the plug connection -2- to the solenoid
Unhook the wiring loom from the holder -3-.
To remove the slide valve body just release the bolts
valves.
2 3 4
marked -arrows A through C- (pay attention to the different lengths when mounting).
When removing the slide valve body the manual slider
-4- remains in the slide valve body.
37-11 page 2

sequence
S37-0089
Edition 07.00
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37
Secure manual slider against dropping out.

Remove O-rings -A-.
Unclip cable guide -arrows-, remove wiring loom for
solenoid valves.
N37-0568
Remove the left and right flange shafts -arrow-.

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

housing.
Remove the O-ring -arrow B- from the gearbox hous-
ing.
Remove the O-ring -arrow C- from the turbine shaft.
N37-0570
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sequence
37-11 page 3
37
Remove the screws -arrows- from the ATF pump.
N37-0573
Remove gasket -1- of the ATF pump from the flange/

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

band -3-.
Unscrew adjusting screw.

Remove brake band.
2
MP 1-202
S37-0091
37-11 page 4

sequence
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37
After removing secure the brake band against spreading open, e.g. with a self-adapted wire hanger -A-.
N38-0109
Remove reverse gear-clutch -1-.
N37-0576
1. Remove 1st to 3rd gear clutch -B- with axial needle

bearing -A-.
N37-0577
Edition 07.00
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sequence
37-11 page 5
37
Remove axial needle bearing -1- from drive shaft -2-.

Pull out drive shaft.
1
2
N37-0578
Remove needle bearing -A- with large sun gear -B-.
A
B
N37-0579
Remove input shaft -1- from the gearbox housing.
N37-0580
37-11 page 6

sequence
Edition 07.00
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37
Rotate gearbox in assembly stand -MP 9-101- 180.

Release the cover screws gradually and crosswise.
Remove cover for gearbox housing
MP 1-202
S37-0092
Remove the O-rings -arrows- from the gearbox hous-
MP 1-202
ing.
3. Remove 3rd and 4th gear clutch -A- with axial needle bearing -B-.
S37-0093
Remove axial needle bearing -A- from planet carrier

-B-.
MP 1-202
Draw out planet carrier.
S37-0094
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sequence
37-11 page 7
37
Remove circlip for reverse gear-brake -B1- with a

screwdriver.
Remove the washers, pressure plate, plates and
MP 1-202
thrust plate of the reverse gear-brake -B1-.
S37-0095
With a screwdriver straighten the tab of the lock washer of the tensioning screw -A-.
MP 1-202
A
S37-0096
Release the tensioning screw from the gearbox hous-
T10003
ing.
MP 1-202
1 - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
S37-0097
37-11 page 8

sequence
Edition 07.00
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37
Remove drive gear with ring gear -A- from the gearbox housing.
Remove the circlip -B- for overrunning clutch -C- with

a screwdriver.
Draw out overrunning clutch together with the thrust

washer from the gearbox housing.
MP 1-202
B
A
Removing drive gear and ring gear Chap. 37-10.
Assembling planetary gear

Insert the axial needle bearing in the correct fitting position Chap. 37-10.
S37-0098
Assembling drive gear and ring gear Chap. 37-10.

Insert overrunning clutch complete with thrust washers -C-.
MP 1-202
Pay attention to the fitting position when inserting the

overrunning clutch Chap. 38-2.
Secure overrunning clutch with circlip -B-.

Install drive gear with ring gear -A- in the gearbox
B
A
housing.
S37-0098
Insert the new lock washer with the pegs of the washer in the gearbox housing holes.
Tighten tensioning screw to 60 Nm.

1 - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
T10003
MP 1-202
S37-0097
Edition 07.00
S00.5318.00.20

sequence
37-11 page 9
37
Secure tensioning screw with lock washer.

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

The planet carrier must only be turned anti-clockwise
(overrunning clutch open).
Place the axial needle bearing -A- in its fitting location
S37-0094
(black surface remains visible) on the planet carrier

-B-.
Install plates -B1- as follows:

First place a suitable pressure plate Chap. 37-12
-5- on the circlip -6-.

Insert inner plates -7- and outer plates -4- of -B1-.
Place thrust plate -3-.
Insert the disc springs -2- in their fitting position (large
diameters point towards one another).

Fit circlip -1-.
1
2
3
7
4
5
6
N38-0106
3. Insert the 3rd through 4th gear-clutch -A-.

Fit new O-rings -arrows- to the gearbox housing.
MP 1-202
A
S37-0116
37-11 page 10

sequence
Edition 07.00
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37
Press spring support plate onto the guide studs of the

piston -B1-.
One guide stud -A- is thicker than the others and thus
holds the spring support plate in place.
Moisten the axial needle bearing -B- with ATF to ensure the bearing sticks to the gearbox housing cover
when fitted.
Insert the axial needle bearing in its fitting position (black
surface remains visible) on the cover.
Apply sealant -D 176 404 A2- to the clean sealing surface of the cover.
The sealant bead must be 34 mm thick.

Fit cover for gearbox housing.
Subsequently, tighten the screws crosswise with 20
N37-0619
MP 1-202
Nm.
Rotate gearbox in assembly stand -MP 9-101- 180.
S37-0092
Insert input shaft -1-.
N37-0580
Edition 07.00
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sequence
37-11 page 11
37
Insert the large sun gear -B- in the gearbox housing.

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

Place the axial needle bearing -1- in its fitting location
(black surface remains visible) on the drive shaft.
1
2
N37-0578
1. Insert the 1st through 3rd gear-clutch -B-.

Insert the axial needle bearing -A- in its fitting position
(black surface remains visible) in the 1st through 3rd
gear-clutch.
When replacing individual components of the planetary
gear, measure the axial needle bearing again Chap.
37-12, adjust clutch clearance..
N37-0577
37-11 page 12

sequence
Edition 07.00
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37
Insert reverse gear-clutch -1-.

To do so the recesses -arrow A- of the reverse gearclutch must catch in the pegs -arrow B- of the large
sun gear.
A
B
S37-0099
Place the adjusting washer -2- on the reverse gearclutch -K1-.

When replacing individual components of the planetary
gear, measure the adjusting washer again Chap. 3712, adjust clutch clearance..
Insert gasket -1- for ATF pump.
2
N37-0574
Install the brake band as follows:
Fit brake band -3-.

Insert new adjusting screw -2- with counternut -1- at
gearbox.
Do not yet screw in the coated part of the screw thread.
Final tightening of the adjusting screw must not occur until the ATF pump has been installed Chap. 37-12, adjust 2nd and 4th gear-brake -B2-.
2
MP 1-202
S37-0091
Edition 07.00
S00.5318.00.20

sequence
37-11 page 13
37
Align ATF pump with gearbox housing. When inserting pay attention to the adjusting washer, gasket for
ATF pump and piston rings of the ATF pump.
Tighten screws of the ATF pump -arrows- to 20 Nm.
N37-0573
Insert the differential gear -arrow A-.

Place new O-rings -arrow B- on the gearbox housing
and insert in turbine shaft -arrow C-.
Apply sealant -D 176 404 A2- to the clean sealing surface of the converter housing.
Position the converter housing on the gearbox housing, pay attention to the fit pin and O-ring of the ATF
pump.
Tighten the converter housing screws to 30 Nm.

Install the left and right flange shafts -arrow-.
Install the plug connection with wiring loom for the so-
N37-0570
MP 1-202
lenoid valves.
S37-0090
37-11 page 14

sequence
Edition 07.00
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37
Moisten the O-rings with ATF.

Insert new O-rings -A- in the gearbox housing.
N37-0617
Fit slide valve body and insert the bolt of the shift segment in the slot of the manual slider -4-.
Tighten screws -arrows A through C- by hand, pay at-
tention to the different screw lengths.

Screws -arrows A- = M6 x 80 mm
Screw -arrow B- = M6 x 68 mm
2 3 4
Screw -arrow C- = M6 x 40 mm
Subsequently, tighten the screws gradually and crosswise to 8 Nm.
Insert plug for the solenoid valves -2-.

Hook wiring loom onto bracket -3-.
Clip on sender -1- for ATF temperature.
S37-0089
Apply sealant -D 176 404 A2- to the oil pan as follows:
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
Apply sealant as shown to the clean sealing surface of

the oil pan.
Run past the area around the bolt holes on the inside
-arrows-.
N17-0019
Edition 07.00
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sequence
37-11 page 15
37
Install oil pan.

Install ATF radiator on gearbox -arrow-.
Installing torque converter Chap. 32-1.
Installing and adjusting multi-function switch Chap.
01-2.
Installing electrical connections and sender on gearbox Chap. 01-2.
MP 9-101
Installing gearbox Chap. 34-7.

Subsequently fill ATF and check ATF level and top up
Chap. 34-8.
Tightening torques
MP 1-202
Oil pan to gearbox housing

ATF radiator to gearbox housing
25 Nm
Flange shaft to gearbox (conical

screw)
22 Nm
Gearshift shaft lever to gearbox
17 Nm
37-11 page 16
S37-0088
8 Nm

sequence
Edition 07.00
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37
37-12 Adjusting work on planetary gear

Overview
I - Reverse gear-brake -B1T A - pressure plate
Determine the thickness
37-12 page 2
II - 2. 2nd and 4th gear-brake -B2T B - brake band
Setting brake band 37-12
page 4
III - Clutch clearance
T C - axial needle bearing
37-12 page 6
T D - adjusting washer
37-12 page 6
II
III
Edition 07.00
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Adjusting work on planetary gear
N37-0603
37-12 page 1
37
Adjusting reverse gear-brake -B1Special tools, test and measuring equipment and aids required
Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Feeler gauge
Install components for adjusting the reverse gear-brake -B1- in the gearbox housing Chap. 37-11.
1 - Gearbox housing
2 - Circlip
T for overrunning clutch
3 - Pressure plate
T install to set
T after measuring install determined thickness
4 - Inner plate -B1T Pieces Chap. 00-1
5 - Outer plate -B1T Pieces Chap. 00-1
6 - Thrust plate
7 - Disc spring
8 - Circlip
9 - Spring support plate
T with springs
T with -B1- piston
T before removing or installing
the cover remove the vehicle
speed sender -G68 Chap. 01-2
11 - 20 Nm
1
7
8
9
10
2
3
4
5
4
5
4
5
4
6
11
N37-0604
37-12 page 2
Edition 07.00
S00.5318.00.20
37
Pressure plate -A- to be measured
Install all components for adjusting the reverse gearbrake -B1- in the gearbox housing 37-12 page 2.
N37-0590
Tighten the screws of the cover to the gearbox housing to 20 Nm.
N37-0581
Blow compressed air into the pressure channel -arrow-. The piston must be heard to compress the plate
packet. Without compressed air the piston must return
to rest position.
N37-0591
Edition 07.00
S00.5318.00.20
37-12 page 3
37
With a feeler gauge -A- measure the clearance between the circlip -1- and the pressure plate -2-.
Clearance:
min. = 0.8 mm
max. = 1.1 mm
N37-0592
A
2. Adjust 2nd and 4th gear-brake -B2Special tools, test and measuring equipment and aids required
Torque wrench (5...50 Nm), e.g. -V.A.G 1331-
Installing components for setting the 2nd and 4th gear-brake -B2- Chap. 37-11.
1 - Gearbox housing
T Planetary gear fitted up to reverse gear-clutch -K2 Chap. 37-11
2 - Adjusting screw
T for brake band -B2T always replace
T bring to system in moulded
part of the brake band -B23 - 45 Nm
4 - Brake band -B25 - Gasket
T for ATF pump
6 - ATF pump
7 - 20 Nm
8 - Spring
9 - Spring
10 - Control piston 2nd and 4th
gear brake
T Insert pressure rod in the
moulded part of the brake
band
11 - Cover
12 - Circlip
8
9
10
11
12
N37-0605
37-12 page 4
Edition 07.00
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37
Tighten screws of the ATF pump -arrows- to 20 Nm.
N37-0573
Adjusting brake band -3-:
Tighten adjusting screw -2- to 5 Nm.

Turn adjusting screw back 2.5 turns.
Tighten nut -1- to 45 Nm, while doing so prevent ad-
justing screw from turning along.
2
MP 1-202
S37-0091
Edition 07.00
S00.5318.00.20
37-12 page 5
37
Setting clutch clearance

Special tools, test and measuring equipment and aids required
Gauge block plate -MP 3-0405/17 Universal dial gauge holder -MP 3-447 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Depth gauge
Straightedge
Dial gauge
Installing components for adjusting the clutch clearance without axial needle brearing -Pos. 3-, adjusting washer
-Pos. 5- and ATF pump -Pos. 7- Chap. 37-11.
Set clutch clearance between -K1- and ATF pump 37-12 page 7
Set clutch clearance between -K2- and ATF pump 37-12 page 8
Perform control measurement (clutch clearance) 37-12 page 10
1 - Gearbox housing
T Planetary gear fitted up to
small drive shaft Chap.
37-11
2 - 1. 1st through 3rd gear clutch
-K1- with turbine shaft
3 - Axial needle bearing with
washer
T Observe the fitting position
Chap. 37-10
T do not install to adjust the
clutch clearance
4 - Reverse gear-clutch -K25 - Adjusting washer
T do not install to adjust the
clutch clearance
6 - Gasket
T for ATF pump
7 - ATF pump
8 - 20 Nm
3
8
N37-0606
37-12 page 6
Edition 07.00
S00.5318.00.20
37
Set clutch clearance between -K1- and ATF

pump
Determine thickness of the axial needle bearing -AThe thickness of the axial needle bearing is determined
by gap size -x- and must be selected according to the table 37-12 page 8
Gap size x = a - b
AD1234-
Axial needle bearing (not fitted for measuring)

Gasket
ATF pump
Reverse gear-clutch -K21. 1st through 3rd gear clutch -K1Gearbox housing
b
x
2
N37-0607
determining a:
Place straightedge -A- on the gearbox housing.

Measure on -K1- with depth gauge -B-.
Example:
Measured value 1 = 54.8 mm
N37-0608
Place gasket -C- on the pump flange of the gearbox

housing.

Measure on pump flange at gearbox housing with
depth gauge -B-.
Example:
Measured value 1
54.8 mm
- Measured value 2
-23.2 mm
determined value a
31.6 mm
N37-0597
Edition 07.00
S00.5318.00.20
37-12 page 7
37
determining b:
Place straightedge -B- on the ATF pump.

Measure on pump flange with depth gauge -A-.
Example:
measured value
33.8 mm
- Straightedge
-5.7 mm
determined value b
28.1 mm
Gap size x = a - b
= 31.6 mm - 28.1 mm = 3.5 mm
N37-0598
Determine thickness of the axial needle bearing according to the table and refer to the spare part catalogue to determine the spare part number.
Axial needle bearing table:

Gap size -x- (mm)
Axial needle bearing

(mm)
2,953,14
3,153,34
3,353,54
3,553,74
3,753,94
3,954,14
2,70
2,90
3,10
3,30
3,50
3,70
d c
y
B
Set clutch clearance between -K2- and ATF

pump
Determining the thickness of the adjusting washer
-BThe thickness of the adjusting washer is determined by
gap size -y- and must be selected according to the table
37-12 page 10
4
3
2
Gap size y = c + d
BD1234-
Adjusting washer (not fitted for measuring)

Gasket
ATF pump
Reverse gear-clutch -K21. 1st through 3rd gear clutch -K1Gearbox housing
N37-0611
determining c:
Place straightedge -A- on the ATF pump.

Measure on pump housing with depth gauge -B-.
Example:
N37-0599
37-12 page 8
Edition 07.00
S00.5318.00.20
37
Measure on pump flange with depth gauge -A-.

Example:

Measured value 1
34.0 mm
- Measured value 2
-33.8 mm
determined value c
0.2 mm
N37-0598
determining d:

Measure on thrust collar of the reverse gear-clutch -
K2- with depth gauge -B-.

Example:
N37-0600
Place gasket -C- on the pump flange of the gearbox

housing.
Measure on pump flange at gearbox housing with

depth gauge -B-.
Example:
Measured value 1
24.7 mm
- Measured value 2
-23.2 mm
determined value d
1.5 mm
Gap size y = c + d
N37-0597
= 0.2 mm + 1.5 mm = 1.7 mm
Determine thickness of the adjusting washer according to the table and refer to the spare part catalogue
to determine the spare part number.
Edition 07.00
S00.5318.00.20
37-12 page 9
37
Table of adjusting washers:

Gap size -y- (mm)
Adjusting washers (mm)
1,351,54
1,551,74
1,751,94
1,952,14
2,152,34
2,352,54
2,552,74
2,752,94
0,80
1,00
1,20
1,40
1,60
1,80
2,00
2,20
Perform control measurement of the clutch clearance

after fitting the ATF pump 37-12 page 10
Control measurement (clutch clearance)
Clutch clearance can only be measured after installing

the ATF pump.
Attach universal dial gauge holder to the gearbox

housing and place dial gauge with 1 mm bias on the
turbine shaft.
Move turbine shaft up and down and read off clear-
MP 3-447
ance on the dial gauge.

Clearance:
min. = 0.25 mm
MP 3-405/17
max. = 0.55 mm
S37-0102
37-12 page 10
Edition 07.00
S00.5318.00.20
38
38 Wheels, Control
38-1
Disassembling and assembling the ATF pump

Measuring device -MP 3-0404/7 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Feeler gauge
Dial gauge
1 - Piston ring
T check correct fitting
T do not over-extend
2 - 10 Nm
3 - Cover for ATF pump
4 - Outer gear
T check for wear Fig. 1 in
38-1 page 2 and Fig. 2 in
38-1 page 2
5 - Inner gear
T check for wear Fig. 1 in
38-1 page 2 and Fig. 2 in
38-1 page 2
6 - Housing for ATF pump
7 - O-ring
T always replace
8 - Gasket ring for torque converter
Chap. 32-1
1
2
3
4
5
6
7
8
N38-0083
Edition 07.00
S00.5318.00.20
38-1 page 1
38
Fig. 1:

Measure the axial wear of the outer and inner gear to the ATF pump housing
Place the measuring device on the ATF pump housing.
If the measured value is greater than the wear limit in
MP 3-404/7
the table replace the relevant gear.

Measuring point
Wear limit mm
Height difference between the ATF

pump housing and outer gear
0,04
Height difference between the ATF

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

gear
A - Feeler gauge 0.5 mm
If the 0.5 mm feeler gauge can be inserted between

the outer and inner gear, replace the gears.
N38-0085
38-1 page 2
Edition 07.00
S00.5318.00.20
38
38-2
Disassembling and assembling overrunning clutch
1 - Thrust washer
T place on clamp body cage
item 2
T smooth side facing outwards
2 - Clamp body cage
T install in outer gear for overrunning clutch Fig. 1 in
38-2 page 2
3 - Outer gear for overrunning
clutch
T Fitting position: Logo and
chamfer -arrow- point towards planet carrier
N38-0086
Edition 07.00
S00.5318.00.20
38-2 page 1
38
Fig. 1:

Assemble overrunning clutch
Lay the outer ring -arrow C- with chamfer -arrow Bpointing downwards on the work table.
Lay the clamp body cage -arrow D- with the conical

guide lugs -arrow A- pointing downwards on the outer
ring.
Press clamp body inwards while pushing the cage

over the guide lugs in the outer ring.
Lay the thrust washers on the clamp body cage.

Inspect operation of overrunning clutch:
Lay aside overrunning clutch in fitting position (logo
and chamfer pointing upwards).

Place the planet carrier in the clamp body cage.
Turn planet carrier to the left: Overrunning gear open

Turn planet carrier to the right: Overrunning gear blocks
S38-0031
38-2 page 2
Edition 07.00
S00.5318.00.20
38
38-3
1. Disassembling and assembling 1st through 3rd gear clutch

-K1-

Pressure plate -MP 3-406 Thrust piece -MP 3-408 Sleeve -MP 3-486/1 Pipe -MP 6-419 Feeler gauge
Inspect operation of clutch Fig. 3 in 38-3 page 2

1 - Circlip
6
T release with a screwdriver
2 - Pressure plate
7
T installing Fig. 2 in 38-3
page 2
T Determine the thickness
Fig. 4 in 38-3 page 3
8
3 - Inner plate
page 2
9
T Pieces Chap. 00-1
4 - Outer plate
10
page 2
11
T Pieces Chap. 00-1
5 - Disc spring
12
page 2
T curved side (smaller diameter) points to clutch bell
6 - Circlip
13
7 - Gasket ring
T always replace
8 - Piston cap
T moisten gasket rings with
ATF before inserting
9 - Spring
T insert between piston and
14
piston cap
10 - Gasket ring
T always replace
T Sealing lip points towards clutch bell
11 - Gasket ring
T always replace
12 - Piston
T differs depending on the engine version
T moisten sealing lips with ATF before inserting
T turn piston slightly when installing
T after installing the piston must turn in the clutch bell
Edition 07.00
S00.5318.00.20
1. Disassembling and assembling 1st through 3rd gear clutch -K1-
1
2
3
4
3
4
3
4
3
4
3
4
5
N38-0088
38-3 page 1
38
13 - Clutch bell with turbine shaft

14 - Piston ring
Fig. 1:
Removing and installing circlip
Press the piston cap with spring down until the circlip
MP 3-408
-arrow- can be inserted in the groove.
MP 6-419
MP 3-486/1
MP 3-406
S38-0020
Fig. 2:
Installing outer and inner plates
Lay the outer plates -2- and inner plates -4- on the disc
spring -3-.
Lay the pressure plate -5- on the last inner plate.

Insert the circlip -1- in the groove of the clutch bell.
5
Fig. 3:
N38-0090
Inspect operation of clutch
With a pneumatic gun blow air in the pressure channel

-arrow-.
Shut off the hole on the opposite side.

The clutch piston must compress the plate packet.
Allow compressed air to escape. The clutch packet
must again return to its rest position.
N38-0091
38-3 page 2
Edition 07.00
S00.5318.00.20
38

Fig. 4:
Determine the thickness of the pressure

plate.
Measure the clearance between the pressure plate

and the circlip with a feeler gauge -A-.
Component
Fitting dimension
Wear limit
Clutch -K1-
0,450.85 mm
1.05 mm
If the wear limit is reached on a used clutch, replace

the plates and measure a new pressure plate.
Assign the plates and pressure plate according to the

Edition 07.00
S00.5318.00.20
N38-0092
38-3 page 3
38
38-3 page 4
Edition 07.00
S00.5318.00.20
38
38-4
Disassembling and assembling the reverse gear-clutch -K2-

Pressure plate -MP 3-407 Thrust piece -MP 3-448 Pressure plate -T10002 Feeler gauge
1 - Circlip
T mark after removing and install again in same position
5
2 - Pressure plate
page 2
6
3 - Inner plate
page 2
T Pieces Chap. 00-1
4 - Outer plate
7
page 2
T Pieces Chap. 00-1
5 - Circlip
8
page 2
9
T with springs
page 2
7 - Gasket ring
T always replace
T Sealing lip points towards
clutch bell
10
8 - Gasket ring
T always replace
9 - Piston
T moisten sealing lips with ATF
before inserting
T Sealing lip points towards clutch bell
10 - Clutch bell
Edition 07.00
S00.5318.00.20
4
N38-0093
38-4 page 1
38
Fig. 1:

Install circlip
MP 3-448
Place the spring support plate on the piston of the -K2clutch.
T10002
Lay circlip on the spring support plate.

Carefully press the circlip with spring support plate
over pressure plate -T10002-, until the circlip is heard
to click into the groove.
MP 3-407
S38-0021
Fig. 2:
Install the outer plates -3- and inner plates -4- in the
clutch bell.

4
N38-0095
Fig. 3:
Place adjusting washer between -K2- clutch and ATF

pump.
Place clutch -K2- on the ATF pump and press downwards.

-arrow-.

N38-0096
38-4 page 2
Edition 07.00
S00.5318.00.20
38

Fig. 4:

plate

Component
Fitting dimension
Wear limit
Clutch -K2-
0.50.8 mm
1.0 mm


Edition 07.00
S00.5318.00.20
N38-0097
38-4 page 3
38
38-4 page 4
Edition 07.00
S00.5318.00.20
38
38-5
Disassembling and assembling 3rd and 4th gear-clutch -K3-
Already when assembling, pay attention Fig. 2 in 38-5 page 2 to the number of plates and their fitting position
Pressure plate -MP 3-407 Thrust piece -MP 3-408 Bushing -MP 3-486/1 Feeler gauge
1 - Circlip
2 - Pressure plate
page 2
T Determine thickness
3 - Inner plate
page 2
T Pieces Chap. 00-1
4 - Outer plate
page 2
T Pieces Chap. 00-1
5 - Circlip
T with springs
7 - Gasket ring
T always replace
8 - Gasket ring
T always replace
9 - Piston
T assigned to gearbox identification characters as a spare
part
T moisten sealing lips with ATF
before inserting
10 - Clutch bell
Edition 04.05
S00.5318.02.20
38-5 page 1
38
Fig. 1:

Removing and installing circlip -arrow-
Carefully press down piston cap until the circlip can be
MP 3-408
removed or installed.
MP 3-486/1
MP 3-407
S38-0022
Fig. 2:
Pay attention to the different number and fitting position of the plates
fig.I -K3- with 3 inner plates

fig.II -K3- with 4 inner plates
A - circlip
B - pressure plate
Fig. 3:
clutch bell.

1
2
3
N38-0100
38-5 page 2
Edition 04.05
S00.5318.02.20
38

Fig. 4:
Lay the axial needle bearing on the cover for the gearbox housing.
Place clutch -K3- on the cover of the gearbox housing

and press downwards.

-arrow-.

N38-0101
Fig. 5:

plate.

Component
Fitting dimension
Wear limit
Clutch -K3-
1,82.2 mm
2.4 mm


Edition 04.05
S00.5318.02.20
N38-0102
38-5 page 3
38
38-5 page 4
Edition 04.05
S00.5318.02.20
38-6
38
Disassembling and assembling the reverse gear-brake -B1-
1 - Gearbox housing
2 - Circlip
3 - Pressure plate
page 2
Chap. 37-12
4 - Inner plate -B19
T Pieces Chap. 00-1
5 - Outer plate -B1T installing Fig. 3 in 38-6
10
page 2
T Pieces Chap. 00-1
6 - Thrust plate
11
7 - Disc spring
12
13
8 - Circlip
14
T with springs
T press onto piston item 12
10 - Gasket ring
T always replace
16 15
11 - Gasket ring
T always replace
16
12 - Piston -B1T differs depending on the engine version
T moisten gasket rings with ATF before inserting
13 - Piston ring
15 - O-ring
T always replace
16 - Plug screw
Edition 07.00
S00.5318.00.20
1
2
3
4
5
4
5
4
5
4
6
7
8
N38-0103
38-6 page 1
38
Fig. 1:

Remove piston -B1-
With a screwdriver lever off piston from gearbox housing cover.
N38-0104
Fig. 2:
Place spring support plate on the piston B1-
Press spring support plate onto the guide studs of the

piston -B1-.
One guide stud -A- is thicker than the others and thus
holds the spring support plate in place.
A
Fig. 3:
N38-0105
Lay pressure plate -5- on circlip -6-, which holds the

overrunning clutch in position.
gearbox housing.
Lay the thrust plate -3- on the last inner plate.

Insert the disc springs -2- in their correct fitting position, large diameters point towards one another.
Insert the circlip -1- in the groove of the gearbox hous-
1
2
ing.
3
7
4
5
6
N38-0106
38-6 page 2
Edition 07.00
S00.5318.00.20
38
38-7
Disassembling and assembling the piston for 2nd and 4th

gear-brake -B2-

Pressure plate -MP 3-453 Screw clamp, commercially available
Wire hanger, self-made
1 - Circlip
2 - O-ring
16
T always replace
15
3 - O-ring
T always replace
14
4 - Cover
T after removing circlip pull out
13
of gearbox housing
5 - O-ring
T always replace
6 - 4. Gear-control piston
T assigned to gearbox identifi9
cation characters as a spare
part
8
7 - O-ring
T always replace
7
8 - O-ring
6
T always replace
9 - Piston cap
5
T for 2nd gear-control piston
T differs depending on the en4
gine version
T assigned to gearbox identification characters as a spare
part
3
2
10 - 2. Gear-control piston
11 - Spring
12 - Spring
13 - Brake band -B2T lay aside in fitting position Fig. 2 in 38-7 page 2
14 - Adjusting screw
T for brake band -B215 - 45 Nm
Edition 07.00
S00.5318.00.20
12
11
10
Disassembling and assembling the piston for 2nd and 4th gearbrake -B2-
S38-0023
38-7 page 1
38
Fig. 1:

Removing and installing circlip
Place the pressure plate -MP 3-453- over the piston

body of the control piston for brake -B2-.
Pretension cover with screw clamp -A-.

Lever off circlip with screwdriver -B-.
MP 3-453
B
S38-0024
Fig. 2:
Laying aside brake band -B2-
After removing secure the brake band against spreading open, e.g. with a self-adapted wire hanger -A-.
N38-0109
38-7 page 2
Disassembling and assembling the piston for 2nd and 4th gearbrake -B2-
Edition 07.00
S00.5318.00.20
38
38-8
Removing and installing slide valve body - Summary of components
Mounting sequence Chap. 37-11

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

Torque wrench (5..0,50 Nm), e.g. -V.A.G 1331 Catch pan
1 - Screw plug, 15 Nm
T Always replace gasket ring
T Checking ATF level and topping up Chap. 37-8
2 - Overflow tube
T remove to drain ATF
Chap. 37-11
3 - 8 Nm
4 - Oil pan
Chap. 37-11
5 - Magnet
T insert on oil pan supports
6 - 8 Nm
T for ATF strainer on slide
valve body
7 - ATF strainer
T to replace remove and install
the oil pan
38-8 page 3
8 - Retaining plate with solenoid
valves -N88- through -N92T replace jointly
38-8 page 4
9 - 8 Nm
T M6 x 35 mm
10 - 8 Nm
T M6 x 68 mm
11 - 8 Nm
T M6 x 12 mm
Edition 07.00
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12
10 11
13
15
16
17
18
19
14
2
20
3
4
5
25
24
23
21
22
Removing and installing slide valve body - Summary of

components
S38-0025
38-8 page 1
38
12 - Solenoid valve -N93T pink

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

replace gasket ring.
After repair screw in screw plug with new gasket ring

to add ATF.
Subsequently fill ATF and check ATF level and top up

Chap. 37-8
N38-0037
38-8 page 2

components
Edition 07.00
S00.5318.00.20
38

Fig. 2:
Slide valve body identification
Identification characters are embossed in identification

tag -arrow-. The identification tag must remain with the
slide valve body.
Removing and installing ATF strainer

Removing
S38-0026
Removing oil pan Chap. 37-11.

Release the screws -arrows A and B-.
Note
Do not interchange the screws -arrows A and B-. Insert in
same location when re-installing.
3
B
Installing
Install holder -1- for plug connection, holder -2- for wir-
ing loom and identification tag -3- as shown in Fig.
Tighten screws -arrows A and B- by hand.

Subsequently, tighten screws gradually crosswise to 8
Nm.
Installing oil pan Chap. 37-11.

S38-0029
Solenoid valve -N93Removing

Release screw -1- and remove wire for solenoid valve
from screw.
Release screws -arrows-.

Release connector -2-.
Pull out solenoid valve -3-.
Installing
Always replace the O-rings of the solenoid valve.

Tighten screw -1- (M6 x 35 mm) and screws -arrows(M6 x 75 mm) to 8 Nm.
S38-0028

Edition 07.00
S00.5318.00.20

components
38-8 page 3
38
Removing and installing retaining plate

with solenoid valves -N88- through -N92Removing

Remove solenoid valve -N93- 38-8 page 3.
Disconnect the plug connection -1- for solenoid valves
and remove plug from holder.
Release the screws -arrows A through C-.

Note
Do not interchange screws -arrow A- (M6 x 35 mm), -arrows B- (M6 x 68 mm) and -arrow C- (M6 x 12 mm). Insert in same location when re-installing.
Installing
Tighten screws -arrows A through C- to 8 Nm.
S38-0027
Install solenoid valve -N93- 38-8 page 3.

38-8 page 4

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

Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Pressure plate -T30030-
Note
To disassemble and assemble the parking position it is necessary to remove the input shaft with parking position gear
and the slide valve body.
1 - Gasket ring
T for gearshift shaft
16
17
T removing Fig. 1 in 38-9
page 2
page 2
2 - Gearshift shaft
T when transporting the gearbox avoid axial impact
14 15
shocks to the gearshift shaft,
screw item 3 could be
sheared off
3 - 10 Nm
T locks the gearshift shaft in
13
the gearbox housing
4 - Spring for shift segment
T do not over-press
11
12
5 - 5 Nm
6 - Shift segment
7 - Tensioning sleeve
10
T for shift segment
T drive out with drift
T drive in after inserting the
shift segment Fig. 3 in
38-9 page 2
9
T with lever item 9
8
7 6
T drive in after inserting the
shift segment Fig. 3 in
38-9 page 2
9 - Lever
T assemble with engaging lever item 10 before installing on gearshift shaft
10 - Engaging lever
T position on gearshift shaft together with lever
11 - 27 Nm
12 - Support plate
T for engaging lever
13 - 5 Nm
14 - Cover plate
T secures axle for locking lever
Edition 07.00
S00.5318.00.20
1
2
3
4
5
N38-0123
38-9 page 1
38
15 - Axle for locking lever

T can be removed and installed by hand
16 - Retracting spring
17 - Locking lever
Fig. 1:
Removing gasket ring for gearshift shaft
N38-0056
Fig. 2:
Driving in gasket ring for gearshift shaft
When installing a new gasket ring moisten the space
T30030
between the sealing lip and dust lip with ATF.
Drive in gasket ring with pressure plate -T30030- up to

the stop.
S38-0030
Fig. 3:
Driving the tensioning sleeves -1- in and out
Driving out
Drive out the tensioning sleeves -1- for lever -4- and
gearshift segment -5- until the gearshift shaft -2- can
be pulled out.
Driving in
After inserting the gearshift shaft in the shift segment

and lever, drive in the tensioning sleeves until flush.
Lock gearshift shaft with screw -3-.
38-9 page 2
N38-0125
Edition 07.00
S00.5318.00.20
38

Fig. 4:
Removing and installing the locking lever

-3- with retracting spring
Unscrew plug -arrow-.

Remove cover plate -1- and pull out axle for locking lever.
Remove retracting spring -2- and locking lever.

When installing hook the leg of the retracting spring
into the locking lever and allow the other extremity of
the spring to rest against the gearbox housing.
2
3
N38-0126
Edition 07.00
S00.5318.00.20
38-9 page 3
38
38-9 page 4
Edition 07.00
S00.5318.00.20
39
39 Final drive, differential

39-1
Replacing flange shaft

gasket rings

Ejection lever -MP 3-418 Pressure plate -T30033 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Catch pan
Sealant -D 176 404 A2-
Removing
Remove noise insulation below engine/gearbox

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

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

Unscrew the drive shaft from the flange shaft.
Tie up the drive shaft as far as possible. Avoid damaging the paintwork on the drive shaft during this operation.
T30033
Proceed as follows for both gasket rings:

Release fixing screw for flange shaft, to do so secure
flange against turning.
Remove the flange shaft with pressure spring.

Pull out gasket ring for flange shaft with ejection lever
-MP 3-418-.
S39-0198
Drive the new gasket ring in up to the stop, do not twist

the gasket ring.
Moisten the space between the sealing lip and dust lip
with ATF.
Coat screw head of conical screw with sealant

-D 176 404 A2-.
Install flange shaft, tighten screw to 22 Nm.

Note
The lengths of the left and right flange shafts differ.
Do not interchange.
Only remove and install one flange shaft in order to
prevent the large differential bevel gears in the differential gear from turning.
Edition 07.00
S00.5318.00.20
Replacing flange shaft gasket rings
39-1 page 1
39
Screw the left drive shaft or right drive shaft to the

flange shaft.
With the gearbox installed check ATF level and top up

Chap. 37-8.
Tightening torques
Flange shaft to gearbox (conical
screw)
Tighten drive shaft to flange shaft
diagonally across in 2 steps (I and II)
to M81)
1)
22 Nm
I - 10 Nm
II - 40 Nm
Always replace these bolts
39-1 page 2
Replacing flange shaft gasket rings
Edition 07.00
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39
39-2
Disassembling and assembling the final drive
Repair overview of the final drive

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

Pressure plate -MP 3-406 Pressure plate -MP 3-407 Thrust piece -MP 3-408 Pipe section -MP 3-414 Thrust piece -MP 3-423 Thrust piece -MP 3-448 Pressure washer -MP 3-456 Distance sleeve -MP 3-458 Pressure plate -MP 3-4014 Washer -MP 6-415 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Tapered-roller bearing extractor, e.g. -V.A.G 1582- or gripper -V.A.G 1582/7 Interior extractor 46...58 mm, e.g. -Kukko 21/7 Countersupport, e.g. -Kukko 22/2-
Note
To remove the input shaft, first remove the planetary gear up to the large sun gear after removing the torque converter
housing Chap. 37-10.
1 - Torque converter housing
2 - Adjusting washer
Chapter 39-3
3 - Outer ring/tapered-roller bearing
T removing Fig. 1 in 39-2
page 3
page 3
4 - Inner ring/tapered-roller bearing
T remove Fig. 3 in 39-2
page 4
T pressing on Fig. 4 in 39-2
page 4
5 - Drive pinion
00-1
6 - Parking position gear
7 - Output gear
00-1
T pressing off Fig. 5 in 39-2
page 4
T pressing on Fig. 6 in 39-2
page 5
8 - 145 Nm
T always replace
T loosen and tighten Fig. 11
in 39-2 page 6
39-2 page 2
7
8
2
9
3
10
4
11
5
N39-0446
Edition 04.05
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39

T secure Fig. 12 in 39-2 page 7
T remove Fig. 7 in 39-2 page 5
T pressing on Fig. 8 in 39-2 page 5
T installing Fig. 10 in 39-2 page 6
Fig. 1:
Remove outer ring/tapered-roller bearing

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

the torque converter housing
MP 3-456
S39-0165
Edition 04.05
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39-2 page 3
39
Fig. 3:

Removing inner ring/tapered-roller bearing
V.A.G 1582
V.A.G 1582/7
N39-0449
Fig. 4:
Pressing on inner ring/tapered-roller bearing
MP 3-414
MP 3-406
MP 3-407
S39-0166
Fig. 5:
Press off output gear
MP 3-448
MP 3-407
MP 3-406
S39-0170
39-2 page 4
Edition 04.05
S00.5318.02.20
39

Fig. 6:
Press on output gear
MP 3-408
MP 3-458
MP 3-407
S39-0171
Fig. 7:
Removing inner ring/tapered-roller bearing
V.A.G 1582
V.A.G 1582/7
N39-0506
Fig. 8:
Pressing on inner ring/tapered-roller bearing
MP 3-414
MP 3-407
S39-0167
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39-2 page 5
39
Fig. 9:

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

the gearbox housing
Support the gearbox housing with pressure plate

-MP 3-4014 -, directly under the bearing support as
shown in the Fig.
MP 3-423
MP 6-415
MP 3-4014
MP 3-407
S39-0168
Fig. 11: Loosen and tighten hexagon nut
Secure input shaft near the parking position gear in a

vice fitted with protective jaws -A-.
Open catches on the nut -arrows- in Fig. N39-0458

B - Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
N39-0457
39-2 page 6
Edition 04.05
S00.5318.02.20
39

Fig. 12: Secure hexagon nut
Secure the collar of the hexagon nut with drift in the recessed slots of the input shaft -arrows-.
N39-0458
Disassembling and assembling the differential

Pressure plate -MP 3-407 Thrust piece -MP 3-408 Pressure washer -MP 3-413 Ejection lever -MP 3-418 Pressure plate -MP 3-420 Drive bushing -MP 3-427 Pressure plate -MP 3-431 Thrust piece -MP 3-448 Pipe section -MP 3-450 Alignment rails -MP 3-457 Thrust plate -MP 3-464 Thrust plate -MP 3-467 Assembly device -MP 5-400 Pressure pipe -MP 6-408 Drawing ring -T30036/3 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Tapered-roller bearing extractor, e.g. -V.A.G 1582- or gripper -V.A.G 1582/3 Two-arm extractor 46...58 mm, e.g. -Kukko 20/10 Extractor hooks, e.g. -Matra V/170 Interior extractor 46...58 mm, e.g. - Kukko 21/7 Countersupport, e.g. -Kukko 22/2 -
Note
Before installing heat the inner ring of the tapered-roller bearing to 100C.
Replace both tapered-roller bearings together.
When replacing the tapered-roller bearing of the differential housing, gearbox housing or converter housing adjust
the differential Chap. 39-3.
Edition 04.05
S00.5318.02.20
39-2 page 7
39
1 - 22 Nm
29
15
T Coat screw head with seal1
ant -D 176 404 A22 - Right flange shaft
2
28
T do not interchange, the left
and right flange shafts are of
27
3
different lengths
4
3 - Pressure spring for flange
26
shaft
5
4 - Thrust washer
25
T Fitting position: Collar to
24
pressure spring, leg to coni6 7 8 9 10
23
cal ring
22
5 - Conical ring
T with slots for thrust washer
21
catch
11
T Fitting position: Cone to12
wards differential housing
6 - Thrust washer
20
T for small differential bevel
19
9 8
7 6
gear
18
7 - Differential bevel gear small
17
page 10
5
8 - Thrust washer
4
14
T for large differential bevel
3
gear
9 - Differential bevel gear large
16
13
page 10
1
15
10 - Threaded part
S39-0164
T to secure the axle for differential bevel gears
T use drift to drive in and drive out
12 - Axle for differential bevel gears
T do not damage thrust washers when driving in
13 - Flange shaft left
T do not interchange, the left and right flange shafts are of different lengths
14 - Fit pin
T for centering the gearbox housing and torque converter housing
15 - Gasket ring for flange shaft
T before installing moisten space between sealing lips with ATF
T can be replaced with the gearbox installed Chap. 39-1
T remove with -MP 3-418T driving in Chap. 39-1
T removing and installing Chapter 39-1
T coat sealing surfaces with sealant -D176 404 A2- before assembling the gearbox housing and torque converter housing
T press into the gearbox housing Fig. 16 in 39-2 page 10
39-2 page 8
Edition 04.05
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39
19 20 21 22 23 -
24 -
25 26 -
27 28 -
29 -
T press into the differential gear housing Fig. 18 in 39-2 page 11

80 Nm
Differential housing
Pinion for final drive
T Number of teeth Chap. 00-1
Drive wheel for speedometer
T Insert the pegs of the drive gear in the slot of the differential gear housing, straight side facing outwards
Inner ring/tapered-roller bearing
T pressing on Fig. 20 in 39-2 page 12
Outer ring/tapered-roller bearing
T installing Fig. 22 in 39-2 page 12
Adjusting washer
T Determine thickness Chapter 39-3
Guide bush
T for speedometer drive
T only for vehicles without ABS; from 12.02
Drive for speedometer
T only for vehicles without ABS; from 12.02
Torque converter housing
T removing and installing Chapter 39-2
T Removing and installing the oil pipe Fig. 13 in 39-2 page 9
30 Nm
Fig. 13: Removing and installing the oil pipe -1-
Release the fixing screws -arrows- of the clamps on

the oil pipe.
Pull the oil pipe out of the torque converter housing.

When installing press the oil pipe by hand up to the
stop of the torque converter housing.
Tighten fixing screws -arrows- to 6 Nm.
N39-0460
Edition 04.05
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39-2 page 9
39
Fig. 14: Install the differential bevel gears
Oil the thrust washer for the small differential bevel

gears and insert on them.
Insert the small differential bevel gears, drive in the

differential bevel axle.
Drive in new tensioning sleeve.

Oil the thrust washer for the large differential bevel
gears and insert on them.
Fit the threaded part in the large differential bevel

gears.
Insert and swivel the large differential bevel gears into

position with a 180 offset -arrow-.
N39-0461
Fig. 15: Removing inner ring/tapered-roller bearing
A - Two-arm extractor, e. g. -Kukko 20/10- with extraction hook, e. g. -Matra V/170-
MP 3-431
MP 3-413
Fig. 16: Press inner ring/tapered-roller bearing into
the gearbox housing
Support the gearbox housing with a pressure pipe
S39-0169
MP 5-400
-MP 6-408- directly below the bearing support.
MP 6-408
MP 3-420
MP 3-450
MP 3-407
S39-0172
39-2 page 10
Edition 04.05
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39

Fig. 17: Pull off outer ring/tapered-roller bearing
A - Two-arm extractor, e. g. -Kukko 20/10- with extraction hook, e. g. -Matra V/170-
Insert extraction hooks in the recesses on the gearbox

housing.
MP 3-431
MP 3-467
S39-0173
Fig. 18: Press outer ring/tapered-roller bearing into

the differential gear housing
MP 3-408
T30036/3
MP 3-4071
S39-0174
Fig. 19: Removing inner ring/tapered-roller bearing
Fit thrust plate -MP 3-431- on the differential gear

housing.
V.A.G 1582
V.A.G 1582/3
N39-0466
Edition 04.05
S00.5318.02.20
39-2 page 11
39
Fig. 20: Pressing on inner ring/tapered-roller bearing
MP 3-408
Press inner ring/tapered-roller bearing onto the differential gear housing up to the stop.
MP 3-427
MP 3-407
S39-0175
Fig. 21: Pull off outer ring/tapered-roller bearing -CA - Interior extractor 46...58 mm, e.g. -Kukko 21/7B - Countersupport, e.g. -Kukko 22/2-
B
MP 3-457
A
Fig. 22: Press in outer ring/tapered-roller bearing in
the torque converter housing
S39-0176
MP 3-448
MP 3-464
MP 3-407
S39-0177
39-2 page 12
Edition 04.05
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39
39-3
Overview of adjusting works

1 - Input gear
T is paired with the output
gear, replace together
2 - Drive pinion
3 - Tapered-roller bearing for input shaft
T always replace together
T when replacing the taperedroller bearing determine the
adjusting washer again
4 - Adjusting washer for input
shaft
39-3 page 4
5 - Differential
6 - Adjusting washer for differential gear
39-3 page 2
7 - Tapered-roller bearing for differential gear
T always replace together
T when replacing the taperedroller bearing determine the
adjusting washer again
8 - Output gear
T is paired with the drive gear,
replace together
3
3
4
5
7
7
N39-0499
Edition 07.00
S00.5318.00.20
39-3 page 1
39
Adjusting works when replacing individual components

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

Gauge block plate -MP 3-405/17 Pressure plate -MP 3-407 Universal dial gauge holder -MP 3-447 Thrust piece -MP 3-448 Alignment rails -MP 3-457 Thrust plate -MP 3-464 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Interior extractor 46...58 mm, e.g. -Kukko 21/7 Countersupport, e.g. -Kukko 22/2 Dial gauge
The differential gear must be re-set when

Gearbox housing
or
differential gear tapered-roller bearing
have been replaced.

Necessary adjusting work when replacing individual components 39-3 page 2.
Requirements
Removing the planetary gear from the ATF pump

through to the large sun gear Chap. 37-11
Removing the input shaft Chap. 37-11
39-3 page 2
Edition 07.00
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39
Setting
MP 3-448
Press outer ring/tapered-roller bearing without adjusting washer into the torque converter housing.
Insert the differential gear in the gearbox housing.

Position the converter housing and tighten 8 screws to
torque 30 Nm.
MP 3-464
MP 3-407
S39-0177
Set up the measuring device and dial gauge (3 mm

measuring range).
MP 3-447
Insert the dial gauge with 1 mm bias and set on 0.

Move differential gear up and down.
Read off play on dial gauge and note.
MP 3-405/17
Note
Do not turn the differential while measuring as otherwise
the bearings will settle and the measuring result will be inaccurate.
Determining the adjusting washer

S39-0178
The prescribed bearing preload is reached by adding to

the established measured value a constant compression
value (0.16 mm).
Example:
Measured value
0.94 mm
+ compression (constant value)
0.16 mm
= Thickness of the adjusting washer
1.10 mm
Unscrew the torque converter housing and remove

differential gear from gearbox housing.
Remove outer ring/tapered-roller bearing -C- from

torque converter housing
A - Interior extractor 46...58 mm, e.g. -Kukko 21/7B - Countersupport, e.g. -Kukko 22/2-
Determine the adjusting washers according to the ta-
B
MP 3-457
ble 39-3 page 4:
Spare part numbers Spare Part Catalogue
Edition 07.00
S00.5318.00.20
S39-0176
39-3 page 3
39

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

listed in the table, 2 washers corresponding to the measured value may be fitted.
Press in outer ring/tapered-roller bearing with the determined adjusting washers (in the example 1.10
mm).
MP 3-448
Adjusting the input shaft

Gauge block plate -MP 3-405/17-
MP 3-464
MP 3-407
Universal dial gauge holder -MP 3-447 Thrust piece -MP 3-423 Pressure washer -MP 3-456-
S39-0177
Dial gauge extension -T30025/5 Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Dial gauge
The input shaft must be reset if

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

Necessary adjusting work when replacing individual components 39-3 page 2.
Requirements
Removing the planetary gear from the ATF pump

through to the large sun gear Chap. 37-11
Removing oil pan and slide valve body Chap. 3711
39-3 page 4
Edition 07.00
S00.5318.00.20
39
Setting
Press outer ring/tapered-roller bearing without adjusting washer into the torque converter housing.
MP 3-456
Insert the input shaft in the gearbox housing.

Position the converter housing and tighten 8 screws to
torque 30 Nm.
S39-0165
Set up the measuring device and dial gauge (3 mm

measuring range).
Set the dial gauge to 0 with 1 mm bias.
MP 3-447
A - Dial gauge extension (100 mm long) -T30025/5-
Move input shaft up and down with a screwdriver on

the output gear.
Read off play on dial gauge and note (example: 1.02

mm).
Note
Do not turn the input shaft while measuring as otherwise
the bearings will settle and the measuring result will be inaccurate.
MP 3-405/17
S39-0179
Determining the adjusting washer

The prescribed bearing preload is reached by adding to
the established measured value a constant compression
value (0,18 mm).
Example:
Measured value
1.02 mm
+ compression (constant value)
0.18 mm
= Thickness of the adjusting washer
1.20 mm
Determine the adjusting washers according to the table 39-3 page 6:
Spare part numbers Spare Part Catalogue
Edition 07.00
S00.5318.00.20
39-3 page 5
39

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

listed in the table, 2 washers corresponding to the measured value may be fitted.
39-3 page 6
Edition 07.00
S00.5318.00.20

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5

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 Automatic Gearbox 001

List of Supplements to Workshop Manual

Supplement to Basic Edition

Supplement to Rep. - Gr. 00, 01, 37, 38, 39

FABIA 2000 Automatic Gearbox 001

FABIA 2000 Automatic Gearbox 001

- Identification of the gearbox ......................................................................... 00-1

- Identification characters, aggregate assignment, ratios, capacities ........................... 00-1

- Capacity ................................................................................................. 00-1

- Information on the Automatic Gearbox 001 ....................................................... 00-2

- Repair instructions .................................................................................... 00-2

- Explanation of the terms used in this workshop manual. ........................................ 00-2

Function of Self-diagnosis ........................................................................... 01-1

- Function of Self-diagnosis ............................................................................ 01-1

- Self-diagnosis technical data ........................................................................ 01-1

- Vehicle components .................................................................................. 01-2

- Electric/electronic components of the gearbox ................................................... 01-2

Performing self-diagnosis ............................................................................ 01-3

- Test conditions ......................................................................................... 01-3

- Work sequence ........................................................................................ 01-3

- Overview of selectable functions .................................................................... 01-3

- Interrogating and erasing fault memory ............................................................ 01-3

Fault Table and Initiating Basic Setting .......................................................... 01-4

- Fault table .............................................................................................. 01-4

- Initiating basic setting ................................................................................. 01-4

Reading measured value block ..................................................................... 01-5

- List of display groups ................................................................................. 01-5

- Test table ............................................................................................... 01-5

- Solenoid valves and position of the shift elements ............................................... 01-6

Electrical Test ........................................................................................... 01-7

- Test procedure ......................................................................................... 01-7

Torque Converter ....................................................................................... 32-1

- Identification of the torque converter ............................................................... 32-1

- Draining the torque converter ........................................................................ 32-1

- Installing the torque converter ....................................................................... 32-1

Checking shifting points ............................................................................. 37-1

Measure limit speed of the hydraulic converter ................................................. 37-2

Fault finding ............................................................................................. 37-3

01 Self-diagnosis, Electrical Test

Electric/Electronic Components and Fitting Locations

FABIA 2000 Automatic Gearbox 001

- Fault finding table ..................................................................................... 37-3

Inspecting gearshift mechanism ................................................................... 37-4

- Inspecting gearshift mechanism .................................................................... 37-4

Removing and Installing Shift Mechanism ...................................................... 37-5

- Removing and Installing Shift Mechanism ........................................................ 37-5

- Removing and installing the selector lever grip ................................................... 37-5

Disassembling and assembling the gearshift mechanism ................................... 37-6

- Adjusting latch spring with roller .................................................................... 37-6

Removing and installing the gearbox ............................................................. 37-7

- Removing ............................................................................................... 37-7

- Installing ................................................................................................ 37-7

Checking and topping up ATF level ............................................................... 37-8

- Inspecting ATF level .................................................................................. 37-8

- Topping up ATF ....................................................................................... 37-8

- Replacing ATF ......................................................................................... 37-8

Disassembling and assembling the gearbox .................................................... 37-9

- Gearbox with shift elements ......................................................................... 37-9