Diagnosis & Overhaul - 01n & 097 Audi Cabriolet I

APPLICATION & LABOR TIMES

APPLICATION & LABOR TIMES

IDENTIFICATION

Volkswagen Audi Group (VAG) transaxle type is cast into transaxle case above left output shaft flange. Transaxle code and build date are located on front top of transaxle case.

DESCRIPTION & OPERATION

Transaxle includes a 4-speed automatic transmission, a torque converter, a final drive and solenoid-operated valve body. (Scheme 6) Under normal conditions, all shifts are controlled by a Transaxle Control Unit (TCU). (Scheme 14) Fourth gear is an overdrive gear.

Note. TCU may be referred to as Transmission Control Module (TCM).

Type 097 transaxle uses a standard torque converter. During 3rd gear (non-TCU controlled) and 4th gear operation, the 3rd-4th apply clutch is engaged. This locks the impeller shaft and small planetary drive shaft together, creating a direct coupling between the engine and transaxle.

Overdrive (4th gear) is engaged by the 3rd-4th apply clutch and 2nd-4th brake clutch.

During 3rd gear operation (TCU controlled), the transaxle engages 1st-3rd apply clutch and reverse clutch. This engages the turbine shaft to the large planetary drive shaft (through the 1st-3rd and reverse apply clutches), activating the torque converter.

Type 01N transaxle uses a lockup converter that is actuated in 2nd, 3rd and 4th. Overdrive (4th gear) is engaged by the 3rd-4th apply clutch and 2nd-4th brake clutch.

The transmission elements consist of a planetary gear set, one-way roller clutch, 3 apply clutches and 2 brake clutches. (Scheme 7) Power from the transmission is connected to the pinion through drive gears. A ring gear and differential assembly are connected to flanges which spin the drive axles.

The electronic control consists of a TCU (attached to the brake pedal bracket), control solenoids, various sensors and switches. The control solenoids direct oil pressure inside the valve body.

On Type 097, solenoid valves No. 1-4 control the apply and brake clutches. Solenoid valves No. 5 and 7 control shift smoothness. Control solenoid valve No. 6 is a frequency valve and controls the main hydraulic pressure. The TCU controls the main hydraulic pressure by varying the duty cycle.

An ECO/SPORT button (located on gear selector console) changes the shift program. When the ECO/SPORT button is pressed (SPORT mode), this signals the TCU to change the shift program.

The TCU monitors input and output signals. If electrical problems occur, TCU will record faults in TCU memory and may go into fail-safe mode. If TCU enters fail-safe mode, the transaxle will operate manually in reverse, 1st or 3rd gear. In fail-safe mode, 3rd gear operates with gear selector in 2nd, 3rd or "D". The TCU memory can only be read on VAG Tester (1551/1).

The TCU also controls shift-lock system. This system locks the gear selector in Park or Neutral unless the brake pedal is pushed down. The TCU uses a shift-lock control relay to activate a gear-selector mounted solenoid.

Scheme 6

Scheme 7

LUBRICATION & ADJUSTMENTS

Note. See appropriate AUTOMATIC article in TRANSMISSION SERVICING.

AXLE SHAFTS

See appropriate AXLE SHAFTS article in AXLE SHAFTS.

OIL COOLER FLUSHING

1. On Type 097, remove external oil filter. On both types, remove oil lines and allow fluid to drain. Using pressurized solvent, flush remaining fluid and debris from oil lines and cooler. Repeat flushing if necessary.
2. Use pressurized shop air to remove solvent from oil lines and oil cooler. Install a new external oil filter.

TRANSAXLE COMPONENTS

Following components may be serviced with transaxle in vehicle. For removal and installation procedures, see TRANSAXLE DISASSEMBLY .

1. Drive Axle Flanges, Ring Gear & Differential
2. External Oil Filter
3. Gear Selector Lever
4. Multifunction Switch, Speedometer Sender & Speed Sensor
5. Oil Pan & Valve Body Assembly

MECHANICAL, HYDRAULIC & ELECTRICAL CHECKS

1. If gear selector is stuck in Park or Neutral, go to «SHIFT LOCK SYSTEM»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) . If gear positions are missing, shift quality is poor or no shifts are possible, ensure all electrical connections are okay and fluid level is correct.
2. If problems are still present, disconnect electrical connector at transaxle. Test drive vehicle. Check if transaxle will operate manually in reverse and 1st gear. Move gear selector to 2nd, 3rd or "D" position. Transaxle should operate in 3rd gear only in all 3 positions (2nd, 3rd or "D").
3. If transaxle operates as described, problem may be electrical. See «ELECTRONIC SELF-DIAGNOSTICS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__electronic-self-diagnostics) . If transaxle does not operate as described, problem may be mechanical or hydraulic. See «ROAD TEST»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__road-test) in TESTING.

Note. If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear.

APPLY & BRAKE CLUTCH APPLICATION

APPLY & BRAKE CLUTCH APPLICATION (1)

ROAD TEST

Note. Information for Type 01N is not available from manufacturer.

Scheme 8

1. Road test vehicle. Move ECO/SPORT switch to ECO. From a stop, perform full throttle upshifts with transaxle in "D". Note upshift speeds.
2. With vehicle at a speed above kickdown speed, press throttle pedal down and note kickdown shift speeds. Repeat road test with ECO/SPORT switch in SPORT position. Compare vehicle shift speeds to shift speed specifications. See «SHIFT SPEED SPECIFICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.
3. If transaxle does not shift within specified MPH range, determine affected elements. See «APPLY & BRAKE CLUTCH APPLICATION»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__apply-brake-clutch-application). (Scheme 8)
4. If all apply and brake clutch elements are affected, check oil pump, oil filter, cooler lines, solenoid valve No. 6, operation of ECO/SPORT switch, condition of torque converter and/or engine. Repair as necessary.
5. If one or more apply and brake clutch elements are affected, remove valve body. Locate appropriate fluid circuit in transaxle case and valve body. (Scheme 9)- (Scheme 15). Check for leaks and blockage. Repair as necessary.
6. If hydraulic circuits are okay or problems with apply and brake clutch elements are mechanical, repair transaxle.

SHIFT SPEED SPECIFICATIONS

Note. If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

HYDRAULIC PRESSURE TEST

Hydraulic pressure tests or specifications not available from manufacturer. Check operation of apply and brake clutches by air checking fluid passages of valve body and transaxle case. (Scheme 9)- (Scheme 15).

STALL SPEED TEST

Note. Information for Type 01N is not available from manufacturer.

1. Engage parking brake and block drive wheels. Connect tachometer to engine. Warm engine to operating temperature.
2. Press brake pedal down firmly. Move gear selector to "D". Open throttle to wide open throttle position. Note engine speed and release throttle pedal. CAUTION: DO NOT operate engine at stall speed for more than 5 seconds. If you need to repeat stall speed test, wait 20 seconds.
3. Compare measured stall speed with stall speed specification. See «STALL SPEED SPECIFICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table. If stall speed is within range, test is complete.
4. If stall speed is too low, check engine condition and adjustments. If no problems with engine are found, torque converter may be defective. If stall speed is too high, check 1st-3rd apply clutch or one-way clutch for slipping or damage.

STALL SPEED SPECIFICATIONS

OPERATION

1. A mechanical control cable prevents ignition key from being removed unless gear selector is in Park. With ignition key removed, gear selector locks in Park. (Scheme 16) NOTE: If battery is disconnected or discharged, gear selector can be moved out of Park by turning ignition key to START position.
2. All models are equipped with an electronic shift lock system. TCU controls shift lock system. (Scheme 17) This system locks gear selector in Park or Neutral position unless brake pedal is pushed down. TCU uses shift lock control relay to release a solenoid mounted on gear selector assembly.

Note. Shift lock relay will not lock gear selector when vehicle speed is greater than 3 MPH.

Scheme 15

Scheme 16

FUNCTIONAL CHECK

1. With ignition key removed, ensure gear selector cannot be moved from Park. Insert key in ignition switch.
2. Turn ignition switch on. Ensure gear selector can only be moved with brake pedal pressed down. Move gear selector to Neutral position.
3. Without pressing brake pedal, ensure gear selector cannot move out of Neutral. Press brake pedal down. Ensure it is now possible to move gear selector.
4. If shift lock system does not operate as described, adjust gear selector, solenoid and control cable. If shift lock system does not operate after adjustments are made, check electrical system of shift lock system with Tester (VAG 1551/1).
5. See testing information under «ELECTRONIC SELF-DIAGNOSTICS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__electronic-self-diagnostics). (Scheme 24)- (Scheme 29). If any problems are found, service harness or components. If no problems are found, TCU may be defective. If shift lock system still does not operate correctly, check for worn or damaged parts and replace as necessary. (Scheme 18)

Scheme 17

ADJUSTMENT

Note. Perform the following adjustments in order given.

Control Cable

1. Remove cable housing mounting screws at gear selector console. Loosen lock screw.
2. Move gear selector to Drive position. Turn ignition on. Move control cable until a.060" (1.5 mm) feeler gauge fits between lock flap and lock pin. (Scheme 19)
3. Turn ignition off. Turn ignition on. Ensure gap is still.060" (1.5 mm). Turn ignition off and on several times and recheck gap. Install cable housing to gear selector console.

Scheme 18

Gear Selector Solenoid

Move gear selector to Reverse. Remove screws, and raise top of gear selector housing. Ensure gap between gear selector and gear selector solenoid is.04" (1.0 mm). (Scheme 20) If necessary, loosen mounting screws and adjust. DO NOT install top of gear selector housing at this time.

Gear Selector

1. Move gear selector to Neutral. Energize solenoid and ensure lower part of gear selector is centered over solenoid.
2. Install top of gear selector housing. Position gear selector housing so gear selector is centered between Reverse and Drive. (Scheme 21) Tighten gear selector housing screws.

Scheme 19

Scheme 20

1. Remove center console cover. Disconnect negative battery cable and wait 30 seconds. Disconnect voltage supply connector for air bag. Voltage supply connector is located at base of steering wheel on 90, or behind center console side trim on Cabriolet.
2. Using Torx wrench, remove air bag retaining screws from rear side of steering wheel. Remove air bag. Remove steering wheel. Remove dash panel.
3. Place gear selector in Neutral position. Remove cable housing mounting screws at gear selector console.
4. Remove cover from top of ignition switch. Remove spring clip holding cable housing to ignition assembly. Lift and tilt cable housing upward. Rotate control cable 1/4 turn until control cable unhooks from ignition switch. (Scheme 22) NOTE: DO NOT kink control cable. If control cable is kinked, gear selector may not move.
5. Remove clip holding cable housing to A/C-heater housing. Remove cable housing from vehicle. To install cable housing, reverse removal procedure. Adjust control cable. See «ADJUSTMENT»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__adjustment).

Scheme 21

ELECTRONIC SELF-DIAGNOSTICS

1. Electronic control consists of TCU (attached to brake pedal bracket), control solenoids, and various sensors and switches. TCU monitors input and output signals. (Scheme 17)
2. If TCU detects problems in transaxle-related circuits or devices, TCU may record a trouble code in memory. To obtain trouble codes, use VAG Tester (1551/1). (Scheme 23) All trouble code and related testing information are contained in tester. See «DIAGNOSTIC TROUBLE CODE (DTC) DEFINITIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.
3. If tester is not available, turn ignition off. Disconnect TCU harness connector. Install Back-Probe Harness (VAG 1598) between TCU and TCU harness. Measure voltage and resistance between specified terminals of TCU connector. For 097 transmissions, use 38 Pin Adapter (1598/9). (Scheme 24)- (Scheme 26). For 01N transmissions, use 68 Pin Adapter (1598/18). (Scheme 27)- (Scheme 29).
4. If problem is found, service harness or component(s). If no problem is found, TCU may be defective. All testing should be done with components at ambient temperature. All resistance testing is done with Back-Probe Harness (VAG 1598) disconnected. All voltage testing is done with Back-Probe Harness (VAG 1598) connected.

DIAGNOSTIC TROUBLE CODE (DTC) DEFINITIONS

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

REMOVAL & INSTALLATION

See appropriate REMOVAL & INSTALLATION article in AUTOMATIC TRANSMISSIONS.

TORQUE CONVERTER

Remove torque converter. Check torque converter for any wear or damage, and replace if necessary. If torque converter is being reused, fluid must be drained. Slightly tilt torque converter on bench and siphon old fluid from converter.

TRANSMISSION UNIT

1. Remove torque converter. Using Support Plate (VW353 and VW309), mount transaxle on work bench. Remove oil pan and valve body assembly. Remove sealing plug from transaxle case. (Scheme 30)and (Scheme 32).
2. Measure and record turbine shaft end play. (Scheme 31) Remove oil pump bolts. Using two M8 bolts, press oil pump from front of transaxle. (Scheme 34)
3. Remove turbine shaft complete with 2nd-4th brake clutch, support tube, 1st-3rd and reverse apply clutch assemblies. Remove impeller shaft and 3rd-4th apply clutch assembly. (Scheme 34)and (Scheme 35).
4. Remove sealing plug from pinion drive transfer gear end of transaxle. Engage parking gear. Using a screwdriver, lock small sun gear drive shell to large sun gear drive shell. (Scheme 36) Remove bolt from end of small planetary drive shaft, and remove shaft.
5. Remove small sun gear drive shell, large sun gear drive shell, circlips and one-way clutch. Remove planetary carrier and bearing assembly. Remove reverse brake clutch assembly. (Scheme 33)and (Scheme 38).

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

FINAL DRIVE & TRANSFER GEARS

1. Drain gear oil. Attach INCH-lb. torque wrench to a 1 5/8" (41 mm) socket wrench. (Scheme 87) Measure and record total roller bearing turning torque and backlash. These measurements are required if roller bearings, ring gear and pinion gear are reused.
2. Engage parking pawl. Using a 7/8" (22 mm) Allen wrench socket, remove fastener nut. (Scheme 39) Remove pinion drive transfer gear assembly from transaxle case. (Scheme 37)
3. Remove speedometer sender. On left axle flange, remove bolt and remove axle flange. On right axle flange, remove circlip. Using Puller (18-1) and Drift (3236), remove right axle flange. (Scheme 40)
4. Remove differential ring gear cover. Remove differential assembly from transaxle case. (Scheme 37)
5. Remove sealing plug from pinion cover. Using INCH-lb. torque wrench, measure turning force of pinion bearings. Record measurement for reassembly.
6. Ensure parking pawl is engaged. Remove nut from pinion. Remove pinion drive gear cover bolts. Install 2 bolts into threaded holes, and remove cover. (Scheme 41)
7. Using Puller (20-10) and Puller Arms (V 172), remove pinion drive gear. (Scheme 42) Remove parking gear from pinion. Remove pinion and bearing from transaxle.

Scheme 38

Scheme 39

Scheme 40

Scheme 41

FINAL DRIVE

1. Disassemble differential. (Scheme 43) If necessary, apply heat to remove ring gear and bearings from differential housing. To reassemble differential, reverse disassembly.
2. Heat ring gear to 212°F (100°C). Install alignment pins to differential carrier, and install ring gear. (Scheme 44) NOTE: If ring gear and/or bearings are replaced, check differential side bearing preload and ring gear position. See «FINAL DRIVE & TRANSFER GEARS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) under TRANSAXLE REASSEMBLY.
3. Using Puller (VAG 1582) and Bearing Puller Adapter (VAG 1582-6), remove roller bearing from pinion. (Scheme 45) Using hydraulic press, Support (VW 402) and Adapter (VW 20-40), install roller bearing to pinion. (Scheme 46)
4. Check all bearing races in transaxle case. Using hydraulic press, replace bearing race(s). Replace each roller bearing and race as a set.

Scheme 42

Scheme 43

Scheme 44

Scheme 45

OIL PUMP & 2ND-4TH BRAKE CLUTCH PISTON

Note. Information for Type 01N is not available from manufacturer.

Disassemble oil pump and 2nd-4th brake clutch piston. Check for worn or damaged parts and replace as necessary. Replace all seals and reassemble. (Scheme 47)

Note. Specifications not available from manufacturer.

Scheme 46

ONE-WAY CLUTCH

Note. Information for Type 01N is not available from manufacturer.

1. Disassemble one-way clutch. Check for worn or damaged parts and replace as necessary. Compress each spring and install into cage. (Scheme 48)
2. Hold cage assembly with large lugs up. Install cage assembly into outer ring. (Scheme 49) Rotate cage clockwise until lugs touch stop. (Scheme 50) Install piston into outer ring. Piston should rotate freely in counter clockwise direction when installed. (Scheme 51)

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Inspection & Adjustment

1. Inspect planetary carrier, pinion gears, sun gears and related parts for wear or damage. Replace parts as necessary.
2. Assemble sun gear drive shells, planetary carrier, small sun gear, pinion drive transfer gear and all related bearings and washers onto small planetary drive shaft. (Scheme 33)
3. Install adjustment shim, washer and bolt to pinion drive transfer gear end of small planetary drive shaft. Using a screwdriver, lock small sun gear drive shell to large sun gear drive shell. (Scheme 36) Tighten bolt to 22 ft. lbs. (30 N.m).
4. Place assembly on Measuring Plate (VW 472/1). Place Dial Indicator Support (VW 382/7) on top of assembly. (Scheme 52) Measure end play of small sun gear drive shaft.
5. If end play is not.009-.014 (.23-.37 mm), replace adjustment shim. Adjustment shims range from.049 (1.26 mm) to.128" (3.25 mm) in.004" (.10 mm) increments.

Scheme 51

APPLY CLUTCH PLATE APPLICATIONS

Note. Information for Type 01N is not available from manufacturer.

APPLY CLUTCH PLATE APPLICATIONS (097)

REVERSE APPLY CLUTCH

Note. Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation.

Note. Information for Type 01N is not available from manufacturer.

1. Mark circlip for installation reference and remove. Disassemble clutch plates. (Scheme 53) Compress spring support, and remove circlip. Remove clutch piston.
2. Check for worn or damaged parts and replace as necessary. Ensure check ball in clutch housing is not damaged. Piston seal is part of piston. If damaged, replace reverse apply clutch piston. Reassemble reverse apply clutch. See «APPLY CLUTCH PLATE APPLICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.

Note. Assembled clutch clearance specification not available from manufacturer. Ensure thrust plate is installed with shouldered side facing circlip.

Scheme 52

REVERSE & 2ND-4TH BRAKE CLUTCHES

Reverse and 2nd-4th brake clutches are disassembled and reassembled during transaxle disassembly and reassembly. See TRANSAXLE DISASSEMBLY and TRANSAXLE REASSEMBLY .

TRANSAXLE CASE

1. Remove multifunction switch, all seals, manual valve assembly, parking pawl and sensors. If necessary, remove parking pawl pin, detent spring screws and operating rod for manual valve from case. (Scheme 54)- (Scheme 60). Inspect bushings and bearing races, and replace if necessary.
2. Install new "O" ring to gear change shaft. Install gear change shaft. Install parking pawl pin (if removed). Using a center punch, peen parking pawl pin. Install operating rod for manual valve, detent spring screws, multifunction switch and new seals. (Scheme 55)- (Scheme 60).

Note. Install pinion oil seal with higher shoulder facing parking gear. Install pinion oil seal after all differential and transfer gear roller bearing preload adjustments and settings are complete. See FINAL DRIVE & TRANSFER GEARS under TRANSAXLE REASSEMBLY.

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

TRANSFER GEARS

Using Puller (VAG 1582) and Bearing Puller Adapter (VAG 1582-3), remove tapered bearing from pinion drive transfer gear. (Scheme 58) Using hydraulic press, Support (VW 402) and Adapter (VW 40-21), install bearing to pinion drive transfer gear. (Scheme 59) Set pinion drive transfer and pinion drive gears aside.

VALVE BODY

Note. Disassembly and reassembly procedures not available from manufacturer.

1ST-3RD APPLY CLUTCH

Note. Information for Type 01N is not available from manufacturer.

1. Remove support ring. Mark circlip for installation reference, and remove circlip. Disassemble clutch plates. (Scheme 62) Remove diaphragm spring circlip. Compress spring support, and remove circlip. (Scheme 61) Remove spring plates and clutch piston.
2. Remove piston rings from piston. Piston seal is part of piston. If damaged, replace 1st-3rd apply clutch piston. Remove seal rings from turbine shaft. Check for worn or damaged parts and replace as necessary. Ensure check ball in clutch housing is not damaged.
3. Install new seal rings to clutch piston, and install piston in clutch housing. Install plate springs with curved sides facing piston. Install operating ring with curved side facing springs. Compress spring support and install circlip. (Scheme 61)
4. Install diaphragm spring with curved side facing piston. Install circlip. (Scheme 63) Install bottom thrust plate with smooth side facing clutch plate. Install one inner splined and one outer splined clutch plate into clutch housing. (Scheme 62)
5. Place inner plate carrier on bench. Install remaining clutch plates to inner plate carrier. See «APPLY CLUTCH PLATE APPLICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__apply-clutch-plate-applications). Insert top thrust plate with smooth side facing clutch plate. Install support ring and snap in place. (Scheme 64)
6. Install inner plate carrier into clutch housing. Install circlip in clutch housing. (Scheme 65)

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

3RD-4TH APPLY CLUTCH

Note. Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation.

Note. Information for Type 01N is not available from manufacturer.

1. Mark circlip for installation reference and remove. Disassemble clutch plates and round ring. (Scheme 66) Compress spring support ring, and remove circlip. Remove diaphragm spring circlip and diaphragm spring. Remove clutch piston.
2. Remove front impeller seal rings. DO NOT remove inner impeller seal rings unless damaged. Check for worn or damaged parts and replace as necessary.
3. Ensure check ball in clutch housing is not damaged. Piston seal is part of piston. If damaged, replace 3rd-4th apply clutch piston. Reassemble 3rd-4th apply clutch. See «APPLY CLUTCH PLATE APPLICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.

Note. Assembled clutch clearance specification not available from manufacturer. Ensure curved side of diaphragm spring faces piston. Ensure rounded side of round ring and rounded side of thrust plate face each other. Ensure top thrust plate is installed with shouldered side facing circlip.

Scheme 65

Note. Reassembly procedures include bearing and shim adjustments. Perform all steps in the order given. If no parts were replaced, skip adjustment steps and reassemble final drive and transfer gear assemblies using new seals. Heat bearing inner races and ring gear to 212°F (100°C) before installing. Ensure turning torque of complete assembly is within specifications. See ADJUSTMENT & REASSEMBLY (PINION DRIVE TRANSFER GEAR) procedure. If turning torque is not within specifications, check all adjustments.

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Remove pinion assembly. Remove roller bearing races. Install a.06" (1.5 mm) Shim (S2) and roller bearing race into transaxle case. Install roller bearing race (no shim) into differential side cover. (Scheme 37)and Figs. (Scheme 67) - (Scheme 69).
2. Ensure right side axle seal is not installed in transaxle case. Ensure speedometer impulse gear is removed from differential housing. Insert differential housing in transaxle case. Install and tighten differential side cover to transaxle case.
3. Position Adapter Plate (VW 385-17) and Dial Indicator Assembly (VW 387) on transaxle case. (Scheme 70) Move differential housing up and down (DO NOT rotate). Measure and record end play.
4. Add.016" (.40 mm) to end play measured in step 3) to obtain desired roller bearing preload. This gives Shim (S1) thickness for differential cover roller bearing race. (Scheme 37)and (Scheme 67). Shims are available in thicknesses ranging from.02" (.55 mm) to.04" (1.00 mm) in.002" (.05 mm) increments.
5. Remove roller bearing race for differential side cover and install Shim (S1). Install roller bearing race. Apply gear oil to bearings. Install differential side cover.
6. Using INCH-lb. torque wrench, rotate roller bearing 8 turns to seat bearings. Measure turning torque of differential roller bearings. (Scheme 71) See «DIFFERENTIAL ROLLER BEARING SPECIFICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table. Remove differential housing from transaxle case. Install speedometer impulse gear and set aside.

DIFFERENTIAL ROLLER BEARING SPECIFICATIONS

Scheme 70

Note. If replacing pinion and large pinion bearing and race, complete steps 1 - 18 . If reusing pinion and large pinion bearing and race, perform steps 1 - 9 only.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. If reusing pinion and large pinion bearing, DO NOT remove existing Shim (S3) from transaxle case. Go to step 3). If replacing pinion and/or large pinion bearing, install large pinion roller bearing to pinion.
2. Remove large roller bearing race. Place a.06" (1.5 mm) thick Shim (S3) into transaxle case. Install large roller bearing race.
3. Ensure parking lock lug is installed in transaxle case. Install small pinion roller bearing race in pinion cover. (Scheme 72) Install pinion and spacer into transaxle case. (Scheme 37)and (Scheme 67).
4. Install parking gear (rounded side facing pinion drive gear), pinion drive gear and a.094" (2.40 mm) thick Shim (S4) on pinion. (Scheme 73)
5. Install shouldered spacer with wide side facing pinion drive gear. Install pinion cover. Install outer roller bearing. Install pinion nut. (Scheme 74) Tighten pinion cover bolts to 18 ft. lbs. (25 N.m).
6. Engage parking gear. Tighten pinion nut to 177 ft. lbs. (240 N.m). Position Adapter Plate (VW 385-17) and Dial Indicator Assembly (VW 387) on transaxle case. (Scheme 75) Move pinion up and down (DO NOT rotate). Measure and record end play.
7. Add.010" (.25 mm) to end play measured in step 6. This is Shim (S4) thickness required to preload pinion cover roller bearing. (Scheme 67) Shims are available in thickness ranging from.040-.094" (1.00-2.40 mm), in.001" (.025 mm) increments.
8. Remove pinion nut, pinion cover and shouldered spacer. Install Shim (S4). Install shouldered spacer. Apply gear oil to bearings. Install pinion cover and pinion nut. Tighten pinion nut to 250 ft. lbs. (339 N.m) to seat bearings. Loosen nut and retighten to 177 ft. lbs. (240 N.m).
9. Using INCH-lb. torque wrench, rotate roller bearing 8 turns to settle bearings. Measure turning torque of pinion roller bearings. (Scheme 76) See «PINION ROLLER BEARING SPECIFICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.
10. If reusing large pinion roller bearing and Shim (S3), go to «ADJUSTMENT (RING GEAR BACKLASH)»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__adjustment-ring-gear-backlash) procedure. Identify ring gear markings. (Scheme 77) Determine running clearance deviation "r" between pinion and ring gear. See «RING GEAR MARKINGS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.
11. Set ring on Measuring Bar (VW 385-1) to 2.756" (70.0 mm). (Scheme 78) Install Dial Indicator Adapter (VW 385-1) and Bearing Sleeves (VW 385-2) to measuring bar.
12. Install Gauge Extension (VW 385-14) on measuring bar. Using Calibrator (VW-85-30) set gauge extension to 2.33" (59.2 mm). (Scheme 79) Set dial indicator to measuring range of.04" (1.0 mm).
13. Place measuring bar into transaxle case. Install End Plate (VW 385-33) to end of pinion. (Scheme 80) Install differential side cover.
14. Rotate second sliding ring outward until measuring bar can still be moved by hand. This centers measuring bar in differential bearing races.
15. Turn measuring bar until extension tip contacts end plate installed on end of pinion. Turn measuring bar back and forth to sweep extension tip across end plate. (Scheme 81) Record maximum deflection (point of needle return). If deflection point is under.04" (1.0 mm), add this dimension to each existing roller bearing shim. If deflection point is over.04" (1.0 mm), subtract this dimension from each existing roller bearing shim.
16. Subtract "r" (on ring gear) from dimension of each calculation obtained in step 15). This calculates thickness required for each shim to set pinion depth.
17. Shims (S3) are available in thickness ranging from.041-.073" (1.05-1.85 mm), in.002" (.05 mm) increments. Shims (S4) are available in thickness ranging from.040-.094" (1.00-2.40 mm), in.001" (.025 mm) increments. WARNING: Leave pinion seal out until drive pinion transfer gear roller bearing preload is set. Ensure pinion seal is installed during reassembly. See «FINAL DRIVE ASSEMBLY»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097__final-drive-assembly) procedure.
18. Remove pinion, and install large pinion roller bearing Shim (S3). Install pinion. Repeat steps 8 and 9. Record turning torque. This specification is required to set drive pinion transfer gear roller bearing preload.

PINION ROLLER BEARING SPECIFICATIONS

RING GEAR MARKINGS

Adjustment (Ring Gear Backlash)

1. Ensure pinion is installed to correct pinion depth and roller bearing preload. If not, see appropriate steps in «ADJUSTMENT (PINION ROLLER BEARINGS)»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) procedure.
2. Install differential housing and differential side cover. Rotate differential to seat bearings. Mount Dial Indicator Assembly (VW 387) to transaxle case. (Scheme 82)
3. Install Setting Adapters (VW 521-4 and 521-8) on differential. Set Measuring Lever (VW 388) to 2.756" (70.0 mm). Using Bearing Separator (Kukko 172), hold pinion from turning. (Scheme 83)
4. Hold ring gear against pinion. Set dial indicator to zero. Rotate ring gear, and record backlash. Check backlash at 3 more places on ring gear.
5. If backlash readings vary more than.002" (.06 mm), recheck ring gear installation or ring gear and pinion for damage. (Scheme 43)and (Scheme 67). If backlash readings vary less than.002" (.06 mm), ring gear and pinion installation is okay.
6. Backlash should be.006-.010" (.15-.25 mm). If not, calculate shim thickness required to correct ring gear backlash. Shims are available in thickness ranging from.02-.04" (.55-1.00 mm), in.002" (.05 mm) increments.
7. Ensure roller bearing preload is maintained. Install shims and recheck ring gear backlash. (Scheme 82)and (Scheme 83).

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Ensure inner race for roller bearing is installed in transaxle case.
2. Install pinion drive transfer gear with roller bearing and axial needle bearing into transaxle case. (Scheme 37)and (Scheme 67). Align lugs on outer roller bearing to fit between lugs on inner roller bearing. (Scheme 84)
3. Install outer roller bearing (without dished washer or shim) on pinion drive transfer gear. (Scheme 37)and (Scheme 67). Engage parking gear. Using an Allen-head socket, tighten fastener nut to 74 ft. lbs. (100 N.m). (Scheme 85)
4. Remove fastener nut. Using a dial indicator, measure distance between pinion drive transfer gear and inner race of roller bearing. (Scheme 86) Add thickness of dished washer.58" (1.50 mm).
5. Add dished washer thickness to distance measured in step 3. Subtract.007" (.18 mm) to obtain shim thickness for desired roller bearing preload. Shims are available in thickness ranging from.063-.100" (1.60-2.55 mm), in.001" (.025 mm) increments.
6. Install selected shim. Install dished washer with cupped side facing away from fastener nut. Apply ATF to bearings. Install and tighten fastener nut to 185 ft. lbs. (250 N.m) to seat bearings.
7. Using INCH-lb. torque wrench, measure combined turning torque of pinion, differential and transfer gear roller bearings. (Scheme 87) See «TRANSFER GEAR ROLLER BEARING SPECIFICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table.
8. Remove fastener nut. If necessary, select a shim and recheck roller bearing preload. If roller bearing preload is okay, apply Locking Compound (AMV 100 01) to shaft side of roller bearing. (Scheme 88)
9. Align lugs with notches of opposite roller bearing. (Scheme 84) Install axial needle bearing with flat side facing drive shaft. Engage parking gear lug. Install fastener nut and tighten to 185 ft. lbs. (250 N.m).

TRANSFER GEAR ROLLER BEARING SPECIFICATIONS

Scheme 85

Scheme 86

Final Drive Assembly

1. Remove differential assembly. Remove pinion cover, parking gear, pinion drive gear and pinion assembly from transaxle case. Install pinion oil seal with higher shoulder facing parking gear. (Scheme 37)
2. Install Seal Protector (3187) over pinion oil seal. (Scheme 89) Install pinion, and remove seal protector. Install parking gear, pinion drive gear assembly and selected shims. (Scheme 37)and (Scheme 60).
3. Install and tighten pinion nut to 177 ft. lbs. (240 N.m). Using a punch, flatten edge of nut against flat on pinion.
4. Install differential assembly. Install and tighten differential cover bolts to 18 ft. lbs. (25 N.m). Install "O" ring to right drive axle flange.
5. Install circlip to end of axle. Using Puller (VW 3244), install right drive axle flange to transaxle. (Scheme 90) Install left drive axle flange. Tighten attaching bolt to 18 ft. lbs. (25 N.m). Install speedometer sender.

Scheme 87

Scheme 88

TRANSMISSION

Note. Soak all friction-faced clutch plates in ATF for at least 15 minutes before installation. Apply assembly lubrication to all bushings, washers, shims and bearings before installation. (Scheme 33)

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

1. Install "O" ring and planetary carrier. Install small sun gear, axial needle bearing and washers. Install end plate shim. (Scheme 90)
2. Install reverse brake clutch plates. (Scheme 92) See «BRAKE CLUTCH PLATE APPLICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table. Using Assembly Ring (VW 3267), install one-way clutch and secure using circlip. (Scheme 93)and (Scheme 94).
3. Using a feeler gauge, check installed reverse brake clutch clearance. (Scheme 95) Clearance should be.047-.071" (1.2-1.8 mm). If clearance is not as specified, replace end plate shim. End plate shims are available in thicknesses ranging from.04" (1.0 mm) to.07" (1.9 mm) in.004" (.10 mm) increments. More than one shim can be used to obtain correct thickness.
4. Install rubber oil splash shield and lower circlip for support tube. (Scheme 94) Install washers, bearing and large sun gear. Install large sun gear drive shell. (Scheme 96)
5. Install small sun gear drive shell. Install small planetary drive shaft. (Scheme 33), see scheme 92 and (Scheme 97). Using a screwdriver, lock small sun gear drive shell to large sun gear drive shell. (Scheme 98) Install adjustment shim, washer and bolt on end of small planetary drive shaft. Tighten bolt to 22 ft. lbs. (30 N.m).
6. Ensure end play is.009-.014" (.23-.37 mm). If end play is not as specified, recheck assembly or adjustment. See «PLANETARY CARRIER»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) under COMPONENT DISASSEMBLY & REASSEMBLY.
7. Install bearing, washer, and impeller shaft and 3rd-4th apply clutch. (Scheme 99) Install bearing, washer and 1st-3rd apply clutch with turbine shaft assembly. see scheme 96 Install thrust shims on 1st-3rd apply clutch housing. Install reverse apply clutch and support tube. see scheme 97 NOTE: Turbine shaft end play was measured before disassembly. If end play is okay, use original thrust shims. If end play is not okay, calculate difference and install required thrust shims.
8. For checking purposes, install oil pump gasket and oil pump. (Scheme 33) Position dial indicator and Support (VW 387) on transaxle case. (Scheme 100)
9. Position dial indicator on turbine shaft, and apply.040" (1.0 mm) preload. Move turbine shaft up and down. Turbine shaft end play should be.019-.047" (.50-1.20 mm).
10. If end play is okay, go to next step. If end play is not okay, install required thrust shims. Thrust shims are available in thicknesses ranging from.04" (1.0 mm) to.07" (1.8 mm) in.008" (.20 mm) increments. Recheck turbine shaft end play.
11. Remove oil pump and oil pump gasket. Install reverse apply clutch (if necessary) and support tube. Ensure groove on support tube engages wedge of one-way clutch. (Scheme 33)and see scheme 97.
12. Install.12" (3.0 mm) thick outer splined plate into transaxle case. (Scheme 101) Install 3 springs and cap springs. Install 2nd-4th brake clutch plates. (Scheme 102) See «BRAKE CLUTCH PLATE APPLICATIONS»(/audi/cabriolet/i-1991-2000/remont/automatic-trans/#diagnosis-overhaul-01n-097) table. Install 3 spring caps to springs.
13. DO NOT install top outer splined clutch plate. Determine clearance of 2nd-4th brake clutch. Press 2nd-4th brake clutch assembly down. Using a depth gauge, measure distance from top of oil pump flange to 2nd-4th brake clutch (inner splined). (Scheme 103)
14. Place a straightedge across top of piston. Place gasket on oil pump flange. Using depth gauge, measure distance from straightedge to oil pump flange gasket. (Scheme 104) Subtract thickness of straightedge.
15. Subtract distance measured in step 13 from distance calculated in step 14. This gives 2nd-4th brake clutch-to-piston distance.
16. Subtract.14" (3.6 mm) from value calculated in step 15). This determines thickness of last outer splined 2nd-4th brake clutch plate. Outer splined 2nd-4th brake clutch plates are available in thickness ranging from.040-.108" (1.00-2.75 mm), in.010" (.25 mm) increments. NOTE: Factory uses.14" (3.6 mm) value to allow for waved spring washer being installed with 2nd-4th brake clutch plates.
17. Install 3 spring caps and last outer 2nd-4th brake clutch plate. Install waved spring washer. Install oil pump gasket. Install "O" ring to oil pump, and install oil pump. Install pinion sealing plug to transaxle case.
18. Install sealing plug (under valve body) to transaxle case. Move gear change shaft to "P" position. Push manual valve operating lever with manual valve into valve body. Tighten set screw. Install valve body. Install oil filter screen and oil pan. (Scheme 30), (Scheme 32), (Scheme 60), see scheme 103 and see scheme 104. Install torque converter.

BRAKE CLUTCH PLATE APPLICATIONS

Scheme 103

Scheme 104

TRANSMISSION SPECIFICATIONS

TRANSMISSION SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TRANSAXLE DISASSEMBLY
• ELECTRONIC SELF-DIAGNOSTICS
• ROAD TEST
• APPLY & BRAKE CLUTCH APPLICATION
• ADJUSTMENT
• APPLY CLUTCH PLATE APPLICATIONS
• ADJUSTMENT (RING GEAR BACKLASH)
• FINAL DRIVE ASSEMBLY
• TRANSMISSION