Auto Trans Overhaul

AUTO TRANS OVERHAUL - V.A.G. 01V

1998 Volkswagen Passat
This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

1997-98 AUTOMATIC TRANSMISSIONS
Volkswagen/Audi V.A.G. 01V Overhaul
Audi:
1997-98; A4, A4 AWD
1998; A6, A6 AWD
Volkswagen:
1998; Passat

TRANSAXLE APPLICATIONS

Vehicle Make & Model Transaxle Model & Code
Audi
1997-98 A4 …………………………… 01V.DCS (1) & DDT (2)
1997-98 A4 AWD ……………………………………. 01V.CJP
1998 A6 ………………………………………. (3) 01V.DPS
1998 A6 AWD ………………………………………. 01V.DPT
Volkswagen
1998 Passat (1.8L) …………………………….. (4) 01V.DDT
1998 Passat (2.8L) …………………………….. (5) 01V.DRD
(1) - From 4/95, 2.72 differential gearing.
(2) - From 9/96, 3.09 differential gearing.
(3) - From 7/97, 2.91 differential gearing.
(4) - From 4/97, 3.09 differential gearing.
(5) - From 8/97, 2.72 differential gearing.


REAR FINAL DRIVE APPLICATION

Vehicle Make & Model Final Drive Model & Code
1997-98 Audi A4 AWD ……………………………….. 01H.B.ABU
1998 A6 AWD ………………………………………… 01R.CUB


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. See Fig. 1.
fig1.png
Fig. 1: Locating Transaxle Identification Plate
Courtesy of Audi of America, Inc.

DESCRIPTION & OPERATION

TRANSAXLE
Transaxle includes a 5-speed automatic transaxle, a torque
converter with clutch, a final drive and solenoid-operated valve body.
Under normal conditions, all shifts are controlled by a Transaxle
Control Module (TCM), 5th gear is an overdrive. The electronic control
consists of a TCM (located in left plenum chamber), control solenoids,
various sensors and switches. The control solenoids direct oil
pressure inside the valve body. The TCM monitors input and output
signals. If electrical problems occur, TCM will record faults in TCM
memory and may go into fail-safe mode. The TCM memory can only be read
on VAG Tester (1551). The TCM also controls shift-lock system. This
system locks the gear selector in Park or Neutral unless the brake
pedal is pushed down. The TCM uses a shift-lock control relay to
release a gear-selector mounted solenoid.

LUBRICATION & ADJUSTMENTS

NOTE: See appropriate AUTOMATIC TRANSMISSION SERVICING article in
TRANSMISSION SERVICING.

ON-VEHICLE SERVICE

DRIVE AXLE SHAFTS
See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER
CASES.
OIL COOLER FLUSHING

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. Use pressurized shop air to remove
solvent from oil lines and oil cooler. Install a new external oil
filter.

TROUBLE SHOOTING

MECHANICAL & ELECTRICAL CHECKS
CAUTION: When battery is disconnected, Transmission Control Module
(TCM) must be reset to Basic Setting using VAG Tester
(1551).

If gear selector is stuck in Park or Neutral, see AUDI SHIFT
LOCK SYSTEMS article. 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. Check for Diagnostic Trouble Codes
(DTC). See VOLKSWAGEN/AUDI V.A.G. 01V ELECTRONIC CONTROLS article.

FAIL-SAFE FUNCTION

When one or more components or sensors fail, the TCM will
substitute functions and continue to operate. If a critical component
fails, and the TCM is active, transaxle will shift into 4th gear with
torque converter clutch disengaged and entire gear display will light.
Reverse can be engaged and selector lock will not work. If a critical
component fails, and the TCM is inactive, symptoms will be the same,
but OBD codes cannot be accessed.

REMOVAL & INSTALLATION

CENTER DIFFERENTIAL (AWD)

Removal & Installation
1) Disconnect left and right catalysts from rear exhaust
system and press both rear catalysts apart. Remove heat shield from
under drive shaft and loosen drive shaft from transaxle flange. Drain
transaxle fluid from center differential and loosen retaining bolts
for differential and remove. See Fig. 2. Be careful when removing
center differential that torsen differential does not fall out of back
of transaxle.
2) Remove torsen differential completely in direction of
arrow from back of output shaft. See Fig. 3. To install reverse
removal procedure. Inspect sealing surfaces for damage and install new
gasket. Turn torsen differential while installing to ensure correct
spline engagement. Tighten center differential bolts to correct
specification. See TORQUE SPECIFICATIONS. Fill differential with
transmission fluid and check level.

fig2.png
Fig. 2: Removing Center Differential Bolts
Courtesy of Audi of America, Inc.fig3.png
Fig. 3: Removing Torsen Differential Assembly
Courtesy of Audi of America, Inc.

FRONT DIFFERENTIAL COVER

Removal & Installation
1) Remove right front wheel and heat shield for right drive
shaft. Remove right drive shaft. See appropriate AXLE SHAFTS article
in AXLE SHAFTS & TRANSFER CASES. Remove left and right front exhaust
pipes with vibration element. Support transmission with jack and
remove right transmission support. Hold right flange shaft with drift
to keep from turning and remove center bolt of right flange shaft. See
Fig. 4. Place drip tray under transaxle and pull out right flange
shaft.
2) Remove bolts of differential cover in opposite order of
tightening sequence and remove. See Fig. 5. Replace O-ring. To
install, reverse removal procedure. Tighten bolts in 2 stages. Tighten
bolts 1, 2 and 3 by hand. Then tighten bolts 1-12 to final torque
specification in proper sequence. See TORQUE SPECIFICATIONS. Check
gear oil in final drive and top up.

fig4.png
Fig. 4: Removing Right Flange Shaft Center Bolt
Courtesy of Audi of America, Inc.fig5.png
Fig. 5: Differential Cover Bolts Tightening Sequence
Courtesy of Audi of America, Inc.

TORQUE CONVERTER

Removal & Installation
Remove torque converter. Check torque converter for any wear
or damage, and replace if necessary. If torque converter is being
reused, drain old fluid. Tilt converter on bench and siphon out all
fluid.
TRANSAXLE
NOTE: For further information, see appropriate AUTOMATIC
TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

VALVE BODY

Removal & Installation
1) Open drain plug and drain ATF. Remove oil pan bolts
diagonally in stages. remove 2 bolts retaining oil strainer and pull
strainer off valve body. Remove clasp retaining wiring harness
connector and disconnect connector at transaxle Vehicle Speed Sensor
(VSS). See Fig. 7.
2) Only loosen valve body bolts indicated inFig. 8. If other
bolts are loosened, operation of valve body may be affected or valve
body may become separated. Bolts are of different lengths. Ensure they
are properly matched to correct location. Remove valve body and wiring
harness with connector. DO NOT set valve body down on top of transaxle
input speed sensor. Apply petroleum jelly to O-rings of wiring harness
connector and install wiring harness connector into transaxle housing.
3) Install valve body without using force and install pin of
detent washer into groove of selector valve. See Fig. 9. Install clasp
for securing wiring harness connector and ensure complete engagement.
Using proper sequence, tighten valve body bolts by hand first, then
tighten bolts for valve body to 70 INCH lbs. (8 N.m). See Fig. 8.
4) Apply a thin coat of petroleum jelly to gasket on oil
strainer and install oil strainer. Replace oil pan gasket and install
oil pan. Tighten bolts to correct torque specification and tighten
diagonally. See TORQUE SPECIFICATIONS. Change ATF or top up after
repairs. See appropriate AUTOMATIC TRANSMISSION SERVICING article in
TRANSMISSION SERVICING.

fig6.png
Fig. 6: Exploded View Of Valve Body Components
Courtesy of Audi of America, Inc.fig7.png
Fig. 7: Disconnecting Wiring Harness
Courtesy of Audi of America, Inc.fig8.png
Fig. 8: View Of Valve Body Bolts
Courtesy of Audi of America, Inc.fig9.png
Fig. 9: Aligning Selector Valve To Linkage
Courtesy of Audi of America, Inc.

COMPONENT DISASSEMBLY & REASSEMBLY
CENTER DIFFERENTIAL ASSEMBLY
NOTE: Information is not available. For exploded view of center
differential assembly, see Fig. 10.

fig10.png
Fig. 10: Exploded View Of Center Differential
Courtesy of Audi of America, Inc.

TORQUE SPECIFICATIONS


Application Ft. Lbs. (N.m)
Center Differential-To-Transaxle Bolts (AWD) …………… 17 (23)
Center Differential Cover Bolts (FWD) …………………. 17 (23)
Drive Axle Attaching Bolt (Left Side Only) …………….. 18 (25)
Drive Axle Flange Bolts ……………………………… 59 (80)
Torque Converter Nuts ……………………………….. 63 (85)
Transaxle-To-Engine Bolts
10-mm Diameter ……………………………………. 33 (45)
12-mm Diameter ……………………………………. 48 (65)
Transaxle-To-Transaxle Support Bolts ………………….. 30 (40)
INCH Lbs. (N.m)
Oil Filter (In Pan) Bolts …………………………….. 53 (6)
Oil Pan Bolts ……………………………………….. 10 (7)
Valve Body Bolts …………………………………….. 70 (8)

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