Volkswagen 01M Transmission. Manual - part 103

SAFETY PRECAUTIONS

TRANSAXLE DISASSEMBLY

    Service  information  provided  in  this  manual  by
ATSG is intended for use by professional, qualified
technicians.   Attempting repairs or service without
the appropriate training, tools and equipment could
cause injury to you or others.
    The  service  procedures  we  recommend  and
describe  in  this  manual  are  effective  methods  of
performing service and repair on this unit.  Some of
the procedures require the use of special tools that
are designed for specific purposes.
   This manual contains CAUTIONS that you must
observe carefully in order to reduce the risk of injury
to  yourself  or  others.    This  manual  also  contains
NOTES that must be carefully followed in order to
avoid improper service that may damage the vehicle,
tools and/or equipment.

803

168

40-

405

- 1

100

Torque

Converter

Code Letters

TORQUE CONVERTER

1. The transaxle should be steam cleaned on the
outside, to remove any dirt and grease before
disassembly begins.
2. This transaxle can be disassembled very easily
on a work bench without the benefit of holding
fixture for rotation.
3. Remove the torque converter from transaxle,
as shown in Figure 50.
Caution: Use care when removing the torque
converter, to avoid personal injury and/or
damage to converter, as it is heavy.
4. Record the torque converter code letters, as
shown in Figure 50, for future reference.

Figure 50

Continued on Page 43

Note: The illustrations provided in the Assembly
and Disassembly section, are of a VW "09G"
model with the integral cooler, but procedures
are the same on "09K" and "09M" models.

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WARNING: There are not any new "hard parts"
available from the manufacturer for this unit. Only
source will be used aftermarket suppliers.

WWW.ALL-TRANS.BY

TRANSAXLE DISASSEMBLY (CONT'D)

5. Remove the 2 transaxle range switch retaining
bolts and range switch, as shown in Figure 51.
Note: The contact lever adjusting nut must
not be loosened (See Figure 51).
6. Remove the integral cooler (if equipped) and
set aside for flushing.

7. Remove and discard the 2 filter seals (4) & (6),
as shown in Figure 51.
Note: Notice that some models are equipped
with a flow control distributor pipe in the
supply side of cooler, as shown in Figure 51.

Continued on Page 44

0 3

44 2

    For  flow  control,  a  distributor  pipe  is
installed  into  the  supply  side  of  the
Integral Cooler on some models only.
NOTE:   Do not install distributor pipe in
the return side of the Integral Cooler.

2 TRANSAXLE RANGE SWITCH.
3 TRANSAXLE RANGE SWITCH RETAINING BOLTS (2 REQUIRED).
4 INTEGRAL COOLER TO CASE SPECIAL "O" RING SEAL.
5 INTEGRAL COOLER ASSEMBLY.
6 "O" RING SEAL.
7 FLAT WASHER.
8 CONE SHAPED LOCKING WASHER.
9 INTEGRAL COOLER RETAINING BOLT.
10 INTEGRAL COOLER FLOW CONTROL PIPE (SOME MODELS).

CONTACT LEVER

ADJUSTING NUT

Figure 51

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

WWW.ALL-TRANS.BY

917

3C0

007

7CA

1371

0010

917

3C0

7CA

3C0

3A01371

TRANSAXLE DISASSEMBLY (CONT'D)

8. Remove the bottom oil pan bolts (8 on "09G")
and remove the bottom oil pan, as shown in
Figure 52.
9. Remove and discard the bottom oil pan gasket,
as shown in Figure 52.
10. Remove the three oil filter retaing bolts and
remove the oil filter, as shown in Figure 53.
11. If the filter is to be re-used, remove and discard
the filter gaskets as shown in Figure 54, as the
filter gaskets are included in Transtec® kit.
Note: Replacing the filter is recommended on
every unit and the gaskets come with the new
filter, already glued in place. If the filter is
to be replaced, discard the entire filter.

Continued on Page 36

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

17 OIL FILTER (MODEL DEPENDANT).
20 OIL FILTER RETAINING BOLTS (3 REQUIRED).

11 BOTTOM OIL PAN (MODEL DEPENDANT).
12 OIL PAN "STAND-PIPE" (MODEL DEPENDANT).
13 OIL LEVEL CHECK PLUG SEALING WASHER.
14 OIL LEVEL CHECK PLUG.
15 OIL PAN BOLTS (8 REQUIRED ON "09G").
16 OIL PAN GASKET.

5734

4-0

09G

361

Figure 52

Figure 53

17 OIL FILTER (MODEL DEPENDANT).
20 OIL FILTER RETAINING BOLTS (3 REQUIRED).

WWW.ALL-TRANS.BY

917

017

100

917

3C00

708

371

U3C

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

SOME MODELS USE A

LOCKING TAB WASHER

FOR THE NUT

18 OIL FILTER GASKET.
19 OIL FILTER GASKET.

Figure 54

Figure 55

Figure 56

TRANSAXLE DISASSEMBLY (CONT'D)

12. Remove the internal manual shift lever retaining
nut, using pliers or vice-grip to hold shift lever,
as shown in Figure 55.
Note: There are two different designs of the
manual lever nut, as shown in Figure 56, one
of which has a locking tab washer.
13. Remove the internal manual shift lever from the
manual shaft, as shown in Figure 56.

CAUTION, CAUTION, CAUTION, CAUTION
Before proceeding with the disassembly process it is
"Imperative" that you now log the color of the wires
going to each and every solenoid to use as a reference
for final assembly. The wire colors are different
between models and year of manufacture.

21 MANUAL SHAFT LEVER RETAINING NUT (SOME MODELS).
22 RETAINING NUT LOCKING TAB WASHER (SOME MODELS).
23 MANUAL SHAFT LEVER NUT WITH SHOULDER (SOME MODELS).
24 MANUAL SHAFT LEVER CENTERING WASHER (SOME MODELS).
25 INTERNAL MANUAL SHAFT LEVER.

Continued on Page 46

WWW.ALL-TRANS.BY

Content .. 101 102 103 104 ..