Manual de Reparação de Transmissões Automáticas: Guia Detalhado para Mecânicos, Esquemas de Sistemática

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Repair Manual

Jetta 1999 ➤

Golf 2000 ➤

Jetta Wagon 2001 ➤

Automatic Transmission

Edition 07.

Service

Service Department. Technical Information

List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups

R e p a i r G r o u p

00 - General, Technical Data

32 - Torque Converter

37 - Controls, Housing

38 - Gears, Hydraulic Controls

39 - Final Drive, Differential

Technical information should always be available to the foremen and mechanics, because their

careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and

safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a

matter of course, be observed.

Service

• 00 - General, Technical Data
  • 1 General Information
  • 1.1 General Repair Instructions
  • 1.2 Transmission Identification
  • 1.3 09A Transmission Information
  • 2 Specifications
  • 2.1 Identification Codes, Engine Allocation, Ratios and Equipment
  • 2.2 Transmission and Final Drive Fluid Capacities
• 32 - Torque Converter
  • 1 General Information
  • 1.1 Torque Converter Identification
  • 1.2 Torque Converter, Draining
  • 2 Removal and Installation
  • 2.1 Torque Converter Oil Seal
  • 2.2 Torque Converter, Installing
  • 3 Special Tools
• 37 - Controls, Housing
  • 1 General Information
  • 1.1 Selector Elements, Position
  • 1.2 Selector Lever Cable, Checking and Adjusting
  • 1.3 Locking Cable, Adjusting
  • 1.4 Transmission, Securing to Repair Stand
  • 1.5 Transmission, Securing to VAS 6095 or VW
  • 2 Description and Operation
  • 2.1 Volkswagen Tester, Connecting and Selecting Functions
  • 2.2 Electrical and Electronic Components and Locations
  • 2.3 Shift Mechanism Assembly Overview
  • 2.4 ATF Cooler Assembly Overview
  • 2.5 Transmission Assembly Overview
  • 3 Specifications
  • 3.1 Tightening Specifications
  • 4 Diagnosis and Testing
  • 4.1 ATF Level, Checking and Filling
  • 4.2 Selector Mechanism, Checking
  • 4.3 Ignition Key Lock, Checking Operation
  • 4.4 Transmission, Checking
  • 5 Removal and Installation
  • 5.1 Selector Lever Handle
  • 5.2 Gear Selector Mechanism
  • 5.3 Shift Lock Solenoid
  • 5.4 Selector Lever Cable
  • 5.5 Locking Cable
  • 5.6 ATF Cooler
  • 5.7 Transmission, Removing
  • 5.8 Transmission, Installing
  • 6 Disassembly and Assembly
  • 6.1 Transmission
  • 7 Special Tools
• 38 - Gears, Hydraulic Controls - Automatic Transmission - Edition 07.
  • 1 General Information
  • 1.1 Brake B2 Piston Housing Cover and Seals
  • 1.2 B2 Piston Installed Locations
  • 2 Description and Operation
  • 2.1 Valve Body Assembly Overview
  • 2.2 Transmission Housing Cover Assembly Overview
  • 2.3 Brake B4 Pressure Accumulator Assembly Overview
  • 3 Specifications
  • 3.1 Fastener Tightening Specifications
  • 4 Removal and Installation
  • 4.1 Multifunction Transmission Range Switch
  • 4.2 Selector Shaft Oil Seal
  • 4.3 Valve Body
  • 4.4 Solenoid Valves
  • 4.5 Transmission Sensors
  • 5 Disassembly and Assembly
  • 5.1 1st through 3rd Gears, K1 Clutch
  • 5.2 Reverse Gear Clutch K2 and 3rd through 5th Gear Clutch K3
  • 5.3 5th Gear, K4 Clutch
  • 6 Special Tools
• 39 - Final Drive, Differential
  • 1 Description and Operation
  • 1.1 Flange Shaft and Seal Assembly Overview
  • 2 Specifications
  • 2.1 Fastener Tightening Specifications
  • 3 Removal and Installation
  • 3.1 Left Flange Shaft and Seal
  • 3.2 Right Flange Shaft and Seal
  • 4 Special Tools
    • Automatic Transmission - Edition 07.

00 – General, Technical Data

1 General Information ⇒ “1.1 General Repair Instructions”, page 1 ⇒ “1.2 Transmission Identification”, page 3 ⇒ “1.3 09A Transmission Information”, page 4

1.1 General Repair Instructions To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply during repair work. A number of generally valid instructions applicable to the various repair procedures - which were formerly repeated a number of times at numerous places in the workshop manual - are summar‐ ized here. They apply to this workshop manual. Transmission Check the Automatic Transmission Fluid (ATF) and top off, as necessary when exchanging the automatic transmission. Capaci‐ ties and specifications, refer to ⇒ “2.2 Transmission and Final Drive Fluid Capacities”, page 6. When installing, ensure that the alignment pins are installed cor‐ rectly. Replacement Parts Many parts of this transmission are disassembled for cleaning but they are not always available as replacement parts. To determine which parts are available, refer to the ⇒ Electronic Parts Catalog “ETKA”. Special Tools A summary of the special tools used in the repair manual pre‐ cedes each repair procedure and can be found in “Special Tools”. Volkswagen Testers There are a number of testers available. ♦ Diagnostic operation system -VAS 5051A- ♦ Tester -VAS 5051/11A- ♦ Individual testers -VAS 5051B/13- ♦ Vehicle diagnosis, testing and information system -VAS 5051B- ♦ Vehicle diagnosis and service system -VAS 5052- When the term “test device” or “tester” is used in this repair man‐ ual, these devices are meant. Neither the -VAG 1551- or the -VAG 1552- can be used.

Automatic Transmission - Edition 07.

1. General Information 1

Loosen and tighten bolts and nuts for covers and housings diag‐ onally. Tightening specifications are specified for non lubricated bolts and nuts. The threads of bolts secured with locking fluid must be cleaned with a wire brush. Then install the bolts with locking fluid -AMV 185 100 A1-. Electrical Components When touching a metal object, you have probably at some time received an electrical shock caused by the electrostatic charging of the human body. This charge can disturb the function of elec‐ trical components of the transmission and of the selector mech‐ anism.

• Before beginning work on any electrical components, touch a grounded object. For example, a water pipe or the hoist. Do not directly touch the connectors of electronic components. Guided Fault Finding, OBD and Testing ♦ Before performing repairs on the automatic transmission, de‐ termine the fault cause as accurately as possible using the vehicle diagnosis, testing and information system -VAS 5051- in operating modes “Guided Fault Finding”, “Vehicle self-di‐ agnosis” and “Test instruments”. For other testers, refer to ⇒ page 1. Basic Setting If the -VAS 5051B- or the -VAS 5052- is used for the basic setting, perform the basic setting only in Guided Fault Finding.

1.2 Transmission Identification The 5 speed automatic transmission 09A is installed in the Jetta from 1999 , Golf from 2000 and the Jetta Wagon from 2001 in conjunction with 4 and 6 cylinder engines. Allocation, refer to ⇒ “2.1 Identification Codes, Engine Allocation, Ratios and Equip‐ ment”, page 6. Location on Transmission Codes -arrow 1-. 5 speed automatic transmission 09A -arrow 2-

Automatic Transmission - Edition 07.

1. General Information 3

Code Letters -arrow 1- Example

EYM 27 10 9 I I I I Identification code

Day Month Year 2000 of manufac‐ ture

The transmission code also appears on the vehicle identification plates. Identification number of manufacturer -arrow-

5 speed automatic transmission 09A -arrow 2-

1.3 09A Transmission Information ⇒ “1.3.1 Transmission Repair”, page 5 For information about this automatic transmission, refer to the ⇒ Self Study Program No. 851103 ; 5 speed automatic trans‐ mission 09A/09B. Transmission The 5 speed automatic transmission 09A has five hydraulically actuated forward gears. The 2nd, 3rd, 4th and 5th gears, when locked up, become mechanically driven gears by eliminating the torque converter slip. Torque Converter The torque converter is equipped with a lockup clutch. The lockup clutch locks up depending on load and speed. The 2nd, 3rd, 4th and 5th gears can be driven mechanically (without slip). Automatic Transmission Fluid (ATF) The ATF is filled for life. The ATF need not be changed during a service. ATF is available as a replacement part. Therefore the part number for it can be found in the ⇒ Electronic Parts Catalog “ETKA”. The ATF level in the transmission and final drive is checked and topped off together. Refer to ⇒ “4.1 ATF Level, Checking and Filling”, page 28.

Automatic Transmission - Edition 07.

4 Rep. Gr.00 - General, Technical Data

2 Specifications ⇒ “2.1 Identification Codes, Engine Allocation, Ratios and Equip‐ ment”, page 6 ⇒ “2.2 Transmission and Final Drive Fluid Capacities”, page 6 2.1 Identification Codes, Engine Allocation, Ratios and Equipment Automatic transmission 09A Transmission Identification code

EYN EYP EEF

Manufactured from to

Torque converter Identification code

AAA/DCD AAA/DCD EFJ

Number of plates Inner Outer Inner Outer Inner Outer Clutch -K1- 7 7 7 7 7 7 Clutch -K2- 2 2 2 2 2 2 Clutch -K3- 5 5 5 5 5 5 Clutch -K4- 4 4 4 4 4 4 Brake -B1- 7 6 7 6 7 6 Brake -B2- 3 3 3 3 3 3 Brake band Brake -B3- Piston dia. in mm

Allocation Model Jetta from 1999 , Golf from 2000

Jetta from 1999 , Golf from 2000 Jetta Wagon from 2001

Jetta from 1999, Golf from 2000

Engine 1.8 ltr. - 132 kW 5V Turbo

1.8 ltr. - 132 kW 5V Turbo

2.8 l - 150 kW

2.2 Transmission and Final Drive Fluid Ca‐ pacities Capacity 5 speed automatic transmission 09A Initial filling 7.0 liters (filled for life) Automatic Transmission Fluid (ATF) is available as a replacement part. Therefore the part number for it can be found in ⇒ Electronic Parts Catalog “ETKA”. The transmission and final drive are checked and filled together as described in ⇒ “4.1 ATF Level, Checking and Filling”, page 28.

Automatic Transmission - Edition 07.

6 Rep. Gr.00 - General, Technical Data

Volkswagen Technical Site: http://vwts.ru http://vwts.info

32 – Torque Converter

1 General Information ⇒ “1.1 Torque Converter Identification”, page 7 ⇒ “1.2 Torque Converter, Draining”, page 7

1.1 Torque Converter Identification There are various torque converters. They are identified by codes -arrow-. Allocation of the torque converter to transmission, refer to ⇒ “2.1 Identification Codes, Engine Allocation, Ratios and Equip‐ ment”, page 6.

Torque Converter Codes (Transmission installed)

1.2 Torque Converter, Draining Special tools and workshop equipment required ♦ Oil extraction unit -VAG 1358A- If the Automatic Transmission Fluid (ATF) has become contami‐ nated by abraded material or if a major overhaul of the transmis‐ sion is being performed, drain the torque converter as follows:

• Extract the ATF from the torque converter using the -VAG 1358A- and -VAG 1358A/1-.

Automatic Transmission - Edition 07.

1. General Information 7

The converter is correctly installed when the value of dimension -a- between the transmission housing flange and contact surface of the torque converter bolts is: ♦ 21 mm in 4 cylinder engines ♦ 17 mm in 6 cylinder engines

• It is essential to make sure that dimension -a- is maintained during assembly. The converter is not allowed to slip forwards.

Automatic Transmission - Edition 07.

2. Removal and Installation 9

3 Special Tools Special tools and workshop equipment required ♦ Oil extraction unit -VAG 1358A-

♦ Extractor lever -VW 681-

♦ Thrust piece -T10089-

Automatic Transmission - Edition 07.

10 Rep. Gr.32 - Torque Converter

1.2 Selector Lever Cable, Checking and Ad‐ justing

Checking

• Move the selector lever to the “P” position.

Automatic Transmission - Edition 07.

12 Rep. Gr.37 - Controls, Housing

• Pry the selector lever cable -1- upwards off of the transmission selector lever -4- and lay it down so that the end can move freely. Do not bend or kink the selector lever cable.
• Move the selector lever from the “P” to the “2” position.
• Check the front protective sleeve on the selector lever cable for damage and replace the cable if necessary.
• Move the selector lever to the “P” position.
• Selector lever mechanism and selector lever cable must move freely. Replace the selector lever cable, refer to ⇒ “5.4 Selector Lever Cable”, page 39 , or repair the selector lever mechanism, as necessary.
• Press the selector lever cable onto the selector shaft lever us‐ ing pliers. Replace the clip -3- if it has been removed. Adjusting
• Move the selector lever to the “P” position.
• Loosen the bolt -2- on the front ball socket -1- of the selector lever cable.
• Move the selector shaft lever on the transmission to the “P” position. The locking lever must engage in the parking lock wheel and both front wheels must be blocked (cannot be turned together in a direction).
• Tighten the bolt -2- to 13 Nm.
• Check the selector mechanism. Refer to ⇒ “4.2 Selector Mechanism, Checking”, page 30.

1.3 Locking Cable, Adjusting

Caution

Strictly follow the instructions below for adjusting the locking

cable.

Special tools and workshop equipment required ♦ Adjustment pin for shift lock 3 -3352A- Prerequisites

• Locking cable in the installed position.
• Center console is removed.
• Selector lever in the “P” position.
• Ignition key in the withdrawal position.
• Steering column is back and down.

Automatic Transmission - Edition 07.

1. General Information 13

♦ Transmission support -T10316- ♦ Engine and transmission holder -VAS 6095-

• If necessary, clean the outside surface of the transmission.
• Install the -T10316- to the transmission.
• Set down the transmission, remove it from the hoist and turn the torque converter housing end upwards.
• Install the -3368- to the transmission mounting flange.
• Lift the transmission using the -2024A- and secure it to the - VAS 6095- or -VW 313-. Never turn the transmission without care or the torque converter could fall out. For information on disassembling the transmission on the stand, refer to ⇒ “6.1 Transmission”, page 52.

Automatic Transmission - Edition 07.

1. General Information 15

2 Description and Operation ⇒ “2.1 Volkswagen Tester, Connecting and Selecting Functions”, page 16 ⇒ “2.2 Electrical and Electronic Components and Locations”, page 17 ⇒ “2.3 Shift Mechanism Assembly Overview”, page 20 ⇒ “2.4 ATF Cooler Assembly Overview”, page 23 ⇒ “2.5 Transmission Assembly Overview”, page 24

2.1 Volkswagen Tester, Connecting and Selecting Functions For other testers, refer to ⇒ page 1. Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051- ♦ Diagnosis lead, 3 m with voltage supply -VAS 5051/1- or di‐ agnosis lead, 5 m without voltage supply -VAS 5051/3-

Caution

♦ During a test drive, always secure the testing and meas‐

uring equipment in the back seat.

♦ These devices may be operated only by a passenger dur‐

ing a test drive.

• Install the connector from the tester into the Data Link Con‐ nector (DLC).
• Switch on tester -arrow-. The tester is ready for use when it is possible to choose between buttons Guided functions and Guided Fault Finding on the right of the screen. Depending on equipment and version of the tester, other func‐ tions may be displayed such as: ♦ Elsa ♦ Testing ♦ Self-diagnosis The tester is now ready for use.
• Switch on the ignition.
• Touch a button on the screen to start the desired function.

Automatic Transmission - Edition 07.

16 Rep. Gr.37 - Controls, Housing