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Volkswagen 01M Transmission. Manual - part 59

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

REQUIRES

TRANS-JEL®

ON RETAINER

REQUIRES

TRANS-JEL®

ON RETAINER

Figure 173

See Legend Figure 174

668

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

"09D" UPPER VALVE BODY EXPLODED VIEW

669

670

671

672

673

674

675

676

677

678

679

680

681

682

683

684

685

686

687

688

689

690

691

692

693

694

695

696

697

698

699

700

701

702

703

704

705

706

707

708

709

710

711

712

713

714

715

716

717

718

719

720

721

722

723

724

725

726

727

728

729

730

731

732

733

734

735

736

737

738

739

740

741

742

743

744

745

715A

Available From Sonnax®

Solenoid modulator valves (725) & (733)

are high failure rate items. Check closely

for any bore wear in casting.

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FIGURE 173 AND 175 LEGEND

Figure 174

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

659 ROUND SCREENS   (2 REQUIRED).
660 VALVE BODY SPACER PLATE.
668 UPPER VB TO LOWER VB BOLT, 22 MM (.866") (4 REQUIRED).
669 UPPER VB TO LOWER VB BOLT, 28 MM (1.102") (25 REQUIRED).
670 UPPER VB TO LOWER VB BOLT, 40 MM (1.574") (10 REQUIRED).
671 OIL BAFFLE NUMBER 2.
672 OIL BAFFLE NUMBER 1.
673 UPPER VALVE BODY CASTING.
674 K1 ACCUMULATOR PISTON.
675 K1 ACCUMULATOR PISTON INNER SPRING   (LT BLUE).
676 K1 ACCUMULATOR PISTON OUTER SPRING   (NONE).
677 K1 ACCUMULATOR PISTON BORE PLUG.
678 K1 ACCUMULATOR PISTON BORE PLUG RETAINER.
679 K3/B1 THREE WAY INNER SHUTTLE BALL SEAT.
680 SHUTTLE BALL   (.250" DIAMETER STEEL).
681 K3/B1 THREE WAY OUTER SHUTTLE BALL SEAT.
682 K3/B1 THREE WAY OUTER SHUTTLE BALL SEAT RETAINER.
683 N283 SWITCH VALVE SPRING (PINK).
684 N283 SWITCH VALVE.
685 N283 SWITCH VALVE BORE PLUG.
686 N283 SWITCH VALVE BORE PLUG RETAINER.
687 N90 SWITCH VALVE SPRING (ORANGE).
688 N90 SWITCH VALVE.
689 N90 SWITCH VALVE BORE PLUG.
690 N90 SWITCH VALVE BORE PLUG RETAINER.
691 K3 CONTROL VALVE SPRING   (PINK).
692 K3 CONTROL VALVE.
693 K3 CONTROL VALVE BORE PLUG.
694 K3 CONTROL VALVE BORE PLUG RETAINER.
695 B1 CONTROL VALVE SPRING   (PINK).
696 B1 CONTROL VALVE.
697 B1 CONTROL VALVE BORE PLUG.
698 B1 CONTROL VALVE BORE PLUG RETAINER.
699 K2 CONTROL VALVE SPRING   (PINK).
700 K2 CONTROL VALVE.
701 K2 CONTROL VALVE BORE PLUG.
702 K2 CONTROL VALVE BORE PLUG RETAINER.
703 B2 SWITCH VALVE (MANUAL "1") VALVE.
704 B2 SWITCH VALVE (MANUAL "1") SPRING (WHITE).
705 B2 SWITCH VALVE (MANUAL "1") BORE PLUG.
706 B2 SWITCH VALVE (MANUAL "1") BORE PLUG RETAINER.
707 B2 REGUL ATOR VALVE.
708 B2 REGUL ATOR VALVE SPRING (VIOLET).
709 B2 REGUL ATOR PLUNGER.
710 B2 REGUL ATOR VALVE BORE PLUG.
711 B2 REGUL ATOR VALVE BORE PLUG RETAINER.
712 PRESSURE MODIFIER VALVE.
713 PRESSURE MODIFIER SPRING   (WHITE).
714 PRESSURE MODIFIER RETAINER.
715A NUMBER 2 REL AY VALVE.
715 NUMBER 2 REL AY VALVE.
716 NUMBER 2 REL AY VALVE SPRING (WHITE).
717 NUMBER 2 REL AY VALVE RETAINER.
718 B2 PORT CONTROL VALVE.
719 B2 PORT CONTROL VALVE SPRING   (WHITE).

720 B2 PORT CONTROL VALVE RETAINER.
721 B1 REL AY VALVE SPRING (ORANGE).
722 B1 REL AY VALVE.
723 B1 REL AY VALVE BORE PLUG.
724 B1 REL AY VALVE BORE PLUG RETAINER.
725 SOLENOID MODUL ATOR VALVE B VALVE.
726 SOLENOID MODUL ATOR VALVE B VALVE SPRING (LT BLUE).
727 SOLENOID MODUL ATOR VALVE B VALVE BORE PLUG.
728 SOLENOID MODUL ATOR VALVE B VALVE BORE PLUG RETAINER.
729 K3 REL AY VALVE SPRING (ORANGE).
730 K3 REL AY VALVE.
731 K3 REL AY VALVE BORE PLUG.
732 K3 REL AY VALVE BORE PLUG RETAINER.
733 SOLENOID MODUL ATOR VALVE A VALVE.
734 SOLENOID MODUL ATOR VALVE A SPRING (LT BLUE).
735 SOLENOID MODUL ATOR VALVE A RETAINER.
736 TCC APPLY CONTROL VALVE.
737 TCC APPLY CONTROL BOOST VALVE.
738 TCC APPLY CONTROL BOOST VALVE SPRING (TAN).
739 TCC APPLY CONTROL BOOST VALVE SLEEVE.
740 TCC APPLY CONTROL BOOST VALVE SLEEVE RETAINER.
741 PRIMARY PRESSURE REGULATOR VALVE.
742 PRIMARY PRESSURE REGULATOR VALVE SPRING (PINK).
743 LINE PRESSURE BOOST VALVE.
744 LINE PRESSURE BOOST VALVE SLEEVE.
745 LINE PRESSURE BOOST VALVE SLEEVE RETAINER.
746 LUBE CHECK VALVE SPRING   (PINK).
747 LUBE CHECK VALVE, 9.98 MM (.392") DIAMETER.
748 SECONDARY REG. VALVE PLASTIC CHECK VALVE ASSEMBLY.
749 TCC APPLY LIMIT CHECK VALVE SPRING (VIOLET).
750 TCC APPLY LIMIT CHECK VALVE, 9.98 MM (.392") DIAMETER.
751 N93 SOLENOID LIMIT CHECK VALVE SPRING   (LT. BLUE).
752 N93 SOLENOID LIMIT CHECK VALVE, 11.98 MM (.471") DIAMETER.
753 REVERSE LIMIT CHECK VALVE SPRING   (WHITE).
754 REVERSE LIMIT CHECK VALVE, 9.98 MM (.392") DIAMETER.
755 REVERSE ORIFICE PL ASTIC CHECK BALL, 5.5 MM (.217") DIA.
756 LINE PRESSURE LIMIT CHECK VALVE SPRING   (NONE).
757 LINE PRESSURE LIMIT CHECK VALVE, 9.98 MM (.392") DIAMETER.
758 REGUL ATED EXHAUST CHECK VALVE SPRING (WHITE).
759 REGUL ATED EXHAUST CHECK VALVE, 9.98 MM (.392") DIAMETER.
760 B2 "SMALL" CAVITY PLASTIC CHECK BALL, 5.5 MM (.217") DIA.
761 LUBE RELIEF CHECK VALVE, 9.98 MM (.392") DIAMETER.
762 LUBE RELIEF CHECK VALVE SPRING   (RED).
763 K2 CLUTCH PLASTIC CHECK VALVE ASSEMBLY.
764 B1 CLUTCH PLASTIC CHECK VALVE ASSEMBLY.
765 K3 CLUTCH PLASTIC CHECK VALVE ASSEMBLY.
766 K1 CLUTCH PLASTIC CHECK VALVE ASSEMBLY.
767 DRIVE RANGE ORIFICE PL ASTIC CHECK BALL, 6.35 MM (.250") DIA.
768 COOLER CHECK VALVE.
769 COOLER CHECK VALVE SPRING   (TAN).
770 MANUAL VALVE.
771 MANUAL VALVE BODY CASTING.
772 MANUAL VALVE BODY RETAINING BOLT, 38 MM (1.496") (7 REQ).

SPECIAL NOTE: VALVE NAMES SHOWN WERE

ASSIGNED BY ATSG BASED ON THEIR FUNCTION.

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ENLARGED VIEW

A-3

"09D" UPPER VALVE BODY SMALL PARTS, EXPLODED VIEW

746

747

748

749

750

751

752

753

754

755

756

757

758

759

760

761

762

763

764

765

766

768

769

770

772

771

767

CHECK BALL

NUMBER 767 IS

.250" DIAMETER

CHECK BALL

NUMBER 767 IS

.250" DIAMETER

CHECK BALL

NO. 755 & 760 IS

.217" DIAMETER

CHECK BALL

NO. 755 & 760 IS

.217" DIAMETER

659

660

Figure 175

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Refer to Page 102 For

Spacer Plate Differences

Between The "2-Port" And

"3-Port" Converters

See Legend Figure 174

"A" OR "B"

SPACER PLATE

"A" OR "B"

SPACER PLATE

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SPRING NO. 769
Free Length = .672"
Spring Diameter = .274"
Wire Diameter = .019"
Approx Coils = 10 (TAN)

SPRING NO. 751
Free Length = .700"
Spring Diameter = .407"
Wire Diameter = .035"
Approx Coils = 6 (LT. BLUE)

SPRING NO. 749
Free Length = .610"
Spring Diameter = .249"
Wire Diameter = .029"
Approx Coils = 7 (VIOLET)

SPRING NO. 762
Free Length = .625"
Spring Diameter = .250"
Wire Diameter = .033"
Approx Coils = 8 (RED)

SPRING NO. 756
Free Length = .430"
Spring Diameter = .373"
Wire Diameter = .050"
Approx Coils = 4 (NONE)

SPRING NO. 758
Free Length = .600"
Spring Diameter = .248"
Wire Diameter = .023"
Approx Coils = 11 (WHITE)

SPRING NO. 753
Free Length = .600"
Spring Diameter = .248"
Wire Diameter = .023"
Approx Coils = 11 (WHITE)

SPRIMG NO. 746
Free Length = .685"
Spring Diameter = .346"
Wire Diameter = .042"
Approx Coils = 6 (PINK)

UPPER VALVE BODY SPRING SPECIFICATIONS

SMALL PARTS, WORM TRACK SIDE

Figure 176

Figure 177

VALVE BODY ASSEMBLY (CONT'D)
18. Install the two round screens into spacer plate
             with the plate oriented as shown in Figure 177,
             and the open end of screens toward the spacer
plate.
Note: There are small magnets in the bottom
of the two round screens.
Note: Refer to Page 102 for the spacer plate
differences between the "2-Port" and "3-Port"
torque converters.
19. The screens will snap into spacer plate, ensure
that they are fully seated.
Note: Valve body gaskets are bonded to all 09D
             spacer plates. Ensure that your gaskets are not
damaged.

Continued on Page 99

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

659

660

659 ROUND SCREENS (2 REQUIRED).
660 VALVE BODY SPACER PLATE.

COMPONENT REBUILD (CONT'D)

SPRING NUMBER 676
Free Length = 1.090"
Spring Diameter = .625"
Wire Diameter = .080"
Approx Coils = 6 (NONE)

SPRING NUMBER 687, 721, 729,
Free Length = 1.130"
Spring Diameter = .255"
Wire Diameter = .027"
Approx Coils = 13 (ORANGE)

SPRING NUMBER 683, 691,
695, AND 699.
Free Length = 1.080"
Spring Diameter = .279"
Wire Diameter = .024"
Approx Coils = 10 (PINK)

SPRING NUMBER 726, 734,
Free Length = 1.425"
Spring Diameter = .386"
Wire Diameter = .055"
Approx Coils = 13 (LT BLUE)

SPRING NUMBER 742
Free Length = 1.235"
Spring Diameter = .545"
Wire Diameter = .048"
Approx Coils = 6 (PINK)

SPRING NUMBER 738
Free Length = .750"
Spring Diameter = .220"
Wire Diameter = .028"
Approx Coils = 12 (TAN)

SPRING NUMBER 704, 713,
716, AND 719.
Free Length = 1.130"
Spring Diameter = .297"
Wire Diameter = .030"
Approx Coils = 12 (WHITE)

SPRING NUMBER 708
Free Length = 1.280"
Spring Diameter = .275"
Wire Diameter = .027"
Approx Coils = 21 (VIOLET)

SPRING NUMBER 675
Free Length = 1.070"
Spring Diameter = .425"
Wire Diameter = .062"
Approx Coils = 9 (LT BLUE)

UPPER VALVE BODY SPRING SPECIFICATIONS

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

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