K0550662920-5-Speed Automatic Gearbox Four-Wheel Drive 01V

Service
Workshop Manual
Passat 1997 ➤
Passat Variant 1997 ➤
5-speed automatic gearbox four-wheel drive 01V
Edition 04.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data
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32 - Torque converter
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37 - Controls, housing
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38 - Gears, control
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39 - Final drive - rear differential
39 - Final drive - front differential
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0550662920

Passat 1997 ➤ , Passat Variant 1997 ➤
5-speed automatic gearbox four-wheel drive 01V - Edition 04.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Notes on 5-speed automatic gearbox 01V four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Notes on 5-speed automatic gearbox 01V four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Codes, engine allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Identifying rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Identifying rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Codes, gearbox allocations, ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 »Vorsprung durch Technik« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 Assembly overview - torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 Removing and installing torque converter
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37 - Controls, housing . .s.au. . . .
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1 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.1 Connecting tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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3 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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3.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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3.2 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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3.3 Checking operation of the ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3.6 Assembly overview - dismantling and assembling selector mechanism . . . . . . . . . . . . . . 38

3.7 Dismantling and assembling selector mechanism - Assembly sequence . . . . . . . . . . . . . . 43
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3.8 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 49

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3.9 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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3.10 Removing and installing locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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3.11 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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4 Removing, dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . 59

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4.1 Assembly overview - Dismantling and assembling selector mechanism cover . . . . . . . . . . 59

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4.2 Removing and installing selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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4.3 Dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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5 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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5.1 Removing and installing gearbox for vehicles with 4-cylinder TDI engine with unit injectors
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5.2 Removing and installing gearbox for vehicles with 5-cylinder engines . . . . . . . . . . . . . . . . 79
5.3 Installing and removing gearbox for vehicles with V6 TDI engines . . . . . . . . . . . . . . . . . . 91
5.4 Removing and installing gearbox for vehicles with V6 petrol engine . . . . . . . . . . . . . . . . . . 108
5.5 Removing and installing gearbox (vehicles with 8-cylinder engine) . . . . . . . . . . . . . . . . . . 124
5.6 Transporting automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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5.7 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

5.8 Removing and installing left and right gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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6.3 Renewing ATF lks.w.ag. e.n.A. . . . . . . . . . A.G. d.o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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6.4 AdditionaledATF by check in vehicles with additional ua ATF cooler . . . . . . . . . . . . . . . . . . . . . . . .
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7 Overview
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ss of selector elements with hydraulic control E17c . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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7.2 Position of selector elements with hydraulic control E18/2 . . . . . . . . . . . . . . . . . . . . . . . . 160

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8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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8.1 Removing and installing ATF lines in vehicles with 4-cylinder engines . . . . . . . . . . . . . . . . 161
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8.2 Removing and installing ATF lines in vehicles with 5-cylinder 110 kW engine . . . . . . . . . . 162
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8.3 Removing and installing ATF lines in vehicles with 5-cylinder 125 kW engine . . . . . . . . . . 163
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8.4 Removing and installing ATF lines in vehicles with V6 TDI engine . . . . . . . . . . . . . . . . . . 164
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8.5 Removing and installing ATF lines in vehicles with V6 petrol engine . . . . . . . . . . . . . . . . . . 165
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8.6 Removing and installing ATF lines in vehicles with 8-cylinder fuel injection engine . . . . . . 166
8.7 Removing and installing additional ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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8.8 Cleaning ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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2.1 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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3 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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3.1 Assembly overview - valve body for gearbox with hydraulic control E17 . . . . . . . . . . . . . . 173
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3.2 Assembly sequence of valve body for gearbox with hydraulic control E17 . . . . . . . . . . . . 175
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3.3 Assembly overview - valve body for gearbox with hydraulic control E18/2 . . . . . . . . . . . . 180
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3.4 Assembly sequence for valve body for gearbox with hydraulic control E18/2 . . . . . . . . . . 182
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3.5 Removing and installing internal oil pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.6 Renewing gearbox speed sender G38 or gearbox output speed sender G195 . . . . . . . . 188
3.7 Renewing gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.8 Removing and installing wiring harness in gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.9 Renewing gearbox oil temperature sender (ATF) G93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5 Renewing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
5.1 Renewing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6 Replacing speedometer sender G22 or vehicle speed sender G68 . . . . . . . . . . . . . . . . . . 199
6.1 Renewing sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Dismantling and assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.3 Adjusting propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Renewing oil seals for flange shafts (rear final drive installed) . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3 Renewing oil seal for propshaft flange (rear final drive installed) . . . . . . . . . . . . . . . . . . . . 217
3.1 Renewing oil seal for propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4 Measuring and marking radial run-out on propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . 223
4.1 Measuring radial run-out on propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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5 Measuring and marking radial run-out on propshaft flange (vehicles without threaded hole in
front side of rear final drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
5.1 Measuring radial run-out on propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
6 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.1 Removing and installing rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
7.1 Checking gear oil in rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
8 Dismantling and assembling rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9 Removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
9.1 Removing and installing differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
10 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
11 Removing and installing pinion gear and dismantling and assembling . . . . . . . . . . . . . . . . 246
11.1 Removing and installing pinion gear and dismantling and assembling . . . . . . . . . . . . . . . . 246
12 Adjusting pinion shaft and crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
12.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
12.2 Adjustment and marking of final drive gear sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
12.3 Position of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
12.4 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
12.5 Recommended sequence for new adjustment of final drive gear set . . . . . . . . . . . . . . . . . . 260
12.6 Adjusting drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
12.7 Adjusting crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
13 Definitions: . . . .ge. n. A. G. ..V.ol.ks. w. a.g.e.n .AG
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39 - Final drive r-isefront differential . . .. . . . . . .u.ara.nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
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1 Checking
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1.1 Checking oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
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2 Repairing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

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2.1 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

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2.2 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

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2.3 Replacing front final drive/gearbox housing sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . 289

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2.4 Renewing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

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3 Axle oil in transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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3.1 Checking axle oil in transfer box and replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

3.2 Draining axle oil in transfer box or filling after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
rrectne
4 Repairing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

4.1 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
s
4.2 Renewing seal for rear flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

s o
cial p
4.3 Renewing seal on intermediate flange for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 310
inform
4.4 Renewing seal in intermediate flange for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . 312
mer
atio
4.5 Renewing oil seal in input pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

om
n
c
4.6 Renewing needle bearing for gear wheel 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

i
or
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Contents iii
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Contents
00 – Technical data
1 Gearbox identification
(VRL005725; Edition 04.2013)
The 5-speed automatic gearbox 01V four-wheel drive is installed
in the Passat 1997 ► in combination with 4, 5, 6 and 8-cylinder
engines. Allocation ⇒ page 3
1.1 Gearbox identification
1.1.1 Location of codes on gearbox

. Volkswagen AG
The gearbox codes appear on the type plate on the gen AG of the
abottom does
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gearbox. by
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Gearbox codes and gearbox serial number.
rrectne
Gearbox serial number -arrow 1-
Gearbox designation -arrow 2-
ss o
Code -arrow 3-
cial p
f inform
mer
The gearbox code also appears on the vehicle identification

plates. atio
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1. Gearbox identification 1
2 Notes on 5-speed automatic gearbox

01V four-wheel drive
⇒ Self-study programme No. 180 ; 5-speed automatic gearbox
01V provides extensive information about the operation of this
gearbox.
2.1 Notes on 5-speed automatic gearbox

01V four-wheel drive
2.1.1 Torque converter

The torque converter is equipped with a lock-up clutch. The clos‐
ing of the lock-up clutch is determined by the engine load and
speed and produces very little vibration. The lock-up clutch drives
all forwards gears mechanically without slip.
2.1.2 Gearbox
Volkswagen AG
The 5-speed automatic gearbox 01V four-wheel drive has five wage
n AG. does
hydraulically actuated forward gears. These forward gears are Volks not
gu
by ara
mechanically driven when the lock-up clutch closes, bridging the
ris
ed nte
torque converter. ut
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ss
2.1.3 Automatic gearbox control unit - J217-
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un
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with driving situation gearshifts (fuzzy
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logic)
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The gear change point, which is dependent on the driving situa‐
h re
tion and driving resistance, is determined automatically.
hole
spec
es, in part or in w
Advantages:
t to the co
• Gear changes will be consumption-orientated.
• Maximum engine output is always available.
rrectness of i
• Individual adaptation of gear change points in all driving sit‐
l purpos
uations.
• Gear change points are infinitely variable.
nform
ercia
2.1.4 Gear change point variations for grades

m
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com
An additional gear change map automatically selects gear tion in

r
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thi
changes for gradients dependent upon accelerator pedal position

s
iva
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and driving speed.

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• Gear change map for extreme uphill stretches is matched to

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engine output. t. Cop py
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• Gear change map for extreme downhill stretches is matched p by
co Vo
to the braking effect of the engine.
by lksw
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Prote AG.
2.1.5 Guided fault finding, vehicle self-diag‐

nosis and testing
Before performing repairs on the automatic gearbox, determine
the cause of the fault as accurately as possible using vehicle di‐
agnosis, testing and information system - VAS 5051- in modes of
operation “guided fault finding”, “vehicle self-diagnosis” and “test
instruments”.
2 Rep. gr.00 - Technical data

3 Codes, engine allocations AG. Volkswagen AG d

agen oes
olksw no
Automatic gearbox d by V 5-speed 01Vt gfour-wheel
ua
ran drive
rise tee
Gearbox Identification
ut
ho code CJR DEY or DRN
a ac
ss
Manufactured fro 03.97 02.99 08.97
ce
e
m 05.97 11.99 08.99
nl
pt
du
an
to
itte
y li
erm
ab
Allocation Engine 2.8 l - 142 kW 2.5 l - 110 kW 2.8 l - 142 kW
ility
ot p diesel
wit
, is n
Torque converter Identification code N28 K36 F31
h re
hole
spec
Valve body Identification code Allocate valve body according to gearbox codes
es, in part or in w
using ⇒ Electronic parts catalogue (ETKA) .
t to the co
Allocation rear final drive Identification code CUC CUC CUB
Data bus no yes yes
rrectness of i
Hydraulic control E17 E17 E17
l purpos
For information about this, refer to ⇒ page 24
nform
mercia
Automatic gearbox 5-speed 01V four-wheel drive
at
om
ion
c
Gearbox Identification code DST ECB EKD
in t
or
his
te

a
do
riv
m 05.01 08.00 08.00

p
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or
to
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Cop py
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2.8 l - 140 kW
rig
gh ht
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Torque converter Identification code F31 F31 N28
c by lksw
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Valve body Identification code Allocate valve body according to gearbox codes us‐
ing ⇒ Electronic parts catalogue (ETKA) .
Data bus yes yes yes
Hydraulic control E17 E18/2 E18/2

Gearbox Identification code EMM ETX EUA
m 01.00 08.00 08.00
to
diesel diesel diesel
Torque converter Identification code K36 B45 Q45
Allocation rear final drive Identification code CUC CUC CUC
Hydraulic control E18/2 E17 E18/2

Gearbox Identification code FAP FAR FAS
3. Codes, engine allocations 3


m
to
diesel 2.8 l - 140 kW
Torque converter Identification code Q45 F31 N28
Hydraulic control E18/2 E18/2 E18/2
AG. Volkswagen AG d
agen oes
olksw not
Automatic gearbox ed by 5-speed 01V four-wheel drive guar
V
an
ris tee
Gearbox Identification code autho FAN FER FNM or
ac
Manufactured fro ss 08.00 08.00 08.00
ce
e
nl
m 08.00 08.00 02.03
pt
du
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to
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ab
ility
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diesel diesel
wit
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Torque converter Identification code B45 V43 K36
hole
spec
es, in part or in w
t to the co
Allocation rear final drive Identification code CUC CUC
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Gearbox Identification code EMQ FVE GAK

or
thi
te
Manufactured fro 03.00 06.00 06.01 sd

iva
o
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m 03.00 01.03
rp
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to
f
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ng
t.
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op
Allocation Engine 4.0 l -206 kW 4.0 l -206 kW
4.0 l - 202 kW
C py
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4.0 l - 206 kW
ht
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Torque converter Identification code Q56 Q56 Q56
lksw
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Allocation rear final drive Identification code EUU EUU, GAN EUU, EUT,
GAM

Gearbox Identification code FAU
Manufactured fro 02.03
m
to

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
d
rise 5-speed automatic gearboxnte four-wheel drive 01V - Edition 04.2013
tho eo
s au ra
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s
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Allocation Engine 2.5 l - 132 kW
an
d
itte
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Torque converter Identification code B56
ility
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wit
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spec
Allocation rear final drive Identification code EUS
t to the co
Data bus yes
Hydraulic control E18/2
rrectness o
cial p
f inform
mer
atio
om
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3. Codes, engine allocations 5

4 Identifying rear final drive

Final drive unit 01R is allocated to four-wheel drive automatic
gearbox 01V.
Allocation ⇒ page 6
4.1 Identifying rear final drive

If the rear final drive is to be renewed, it is absolutely necessary
to note the codes of not only the automatic gearbox but also the
engine of the vehicle in ⇒ Genuine Parts Division catalogue. Only
then is a correct allocation guaranteed.
4.1.1 Location on rear final drive

Codes and date of manufacture -arrow 1-
Final drive 01R -arrow 2-
Final drive 01R -arrow 2-
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4.1.2 Codes and manufacturing data for rear

t to the co
final drive
Example: CUB 15 12 6
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I I I I
s
Identification Day Month Year -1996-

s o
code of manufacture
cial p
f inform
mer
Further data may be disregarded.

atio
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4.2 Codes, gearbox allocations, ratios

um
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Rear final drive 01R
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Identification code CUB CUC CUD
cop Vo
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Manufactured Protefrom 08.97 AG.
05.97 05.97
to


2.5 l - 110 kW 2.3 l - 110 kW
2.3 l - 125 kW
2.5 l - 110 kW
2.8 l - 140 kW
2.8 l - 142 kW
Ratio Z2 : Z1 final drive 37 : 9 = 4.111 35 : 9 = 3.889 41 : 9 = 4.555
AG. Volkswagen AG d
agen oes
Drive shaft flange ∅ olksw 100 nmm
ot g 100 mm 100 mm
V
d by ua
r
Allocate according to engine
ris
e and automatic gearbox using ⇒ Genuine ante Parts Division catalogue.
ho eo
aut ra
ss c
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nl
pt
du
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Identification code DUN EUS EUT
ility
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Manufactured from 02.99 02.03 12.01
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to
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spec
es, in part or in w
t to the co
Ratio Z2 : Z1 final drive 37 : 10 = 3.700 37 : 10 = 3.700 35 : 9 = 3.889
Drive shaft flange ∅ 108 mm 108 mm 108 mm
rrectness of i
Allocate according to engine and automatic gearbox using ⇒ Genuine Parts Division catalogue.
l purpos
nform
ercia
Identification code EUU GAM GAN

m
at
om
io
Manufactured from 05.97 08.02 08.02
n
c
in t
r
to 01.03
o
his
ate
Allocation Engine 1.9 l - 96 kW 4.0 l - 199 kW

do
4.0 l - 202 kW
priv
c
4.0 l - 202 kW 4.0 l - 202 kW
um
for
en
ng
t.
Ratio Z2 : Z1 final drive 37 : 9 = 4.111
yi Co
Cop py
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Drive shaft flange ∅ 108 mm
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Allocate according to engine and automatic gearbox using ⇒ Genuine Parts Division catalogue.
lksw
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Prote AG.
4. Identifying rear final drive 7

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Passat 1997 ➤ , Passat Variant
oris 1997 ➤
e nte
h eo
5-speed automatic gearboxaut four-wheel drive 01V - Edition 04.2013 ra
c
ss
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un
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5 Capacities
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5.1 Capacities
h re
hole
spec
es, in part or in w
t to the co
5.1.1 Planetary gearbox
Capacities Planetary gearbox Automatic
rrectness of i
gearbox
l purpos
Initial filling 9.0 l 01V

Change about 2.6 - 3.0 l1) four-wheel
nform
ercia
drive
m
a
Lubricant VW ATF
com
tion in
r
te o
1) Change required only following repair work or removal of oil pan up to 3 litres.
thi
s
iva
do
VW ATF is available as a part.
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cum
fo
en
Container size 0.5 l - Part No. -G 052 162 A1-
ng
t.
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op py
Container size 1.0 l - Part No. -G 052 162 A2- t. C rig
gh ht
pyri by
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Prote AG.
VW ATF (available as a replacement part) is the only ATF that
may be used in the planetary gearbox of four-wheel drive auto‐
matic gearbox 01V.
Checking ATF level or changing ATF ⇒ page 151 .
5.1.2 Front final drive

Capacities Front final drive Automatic
gearbox
Initial filling approx. 0.75 l 01V
Change Filled for life, no change four-wheel
drive
Lubricant Gear oil
SAE 75 W 90
(synthetic oil)
Gear oil SAE 75 W 90 (synthetic oil) is available as a replacement
part.
Container size 1.0 l - Part No. -G 052 145 S2-
Checking gear oil in front final drive ⇒ page 275 .
5.1.3 Transfer box

Capacities Transfer box Automatic
gearbox
Initial filling approx. 0.8 l 01V
Change Filled for life, no change four-wheel
drive
Lubricant Gear oil
SAE 75 W 90
(synthetic oil)
part.


Checking gear oil in transfer box and replenishing ⇒ page 298 .
5.1.4 Rear final drive

Capacities Final drive 01R
Initial filling 1.5 l
Change Filled for life, no change
Lubricant Gear oil
SAE 75 W 90
(synthetic oil)
part.
Checking gear oil in rear final drive ⇒ page 231 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
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5. Capacities 9
6 General repair notes

To ensure flawless and successful gearbox 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 dur‐
ing repair work.
A number of generally valid instructions applicable for the various
repair procedures - which were formerly repeated a number of
times at numerous places in the workshop manual - are summar‐
ised here. They apply to this workshop manual.
6.1 General repair notes
6.1.1 Special tools

A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in “Special tools/Workshop equipment” binder.
The catalogue is also available on CD-ROM and can be ordered
the usual way from Bertelsmann.
6.1.2 Gearbox
AG. Volkswagen
♦ If the automatic gearboxlkhas
swa been exchanged, the
gen AG do
es following
not
fluid levels are to be
db
checked:
yV
o gu
a
e ran
ris tee
– ATF in planetary
ut gearbox ⇒ page 151 .
ho or
sa ac
– Gear oil in front
s
final drive ⇒ page 275 .
ce
le
un
pt
– Gear oil in transfer box ⇒ page 298 .

an
d
itte
y li
rm
ab
– Capacities and specifications ⇒ page 8 .

pe
ility
ot
wit
♦ If rear final drive is renewed, fill it with gear oil to lower edge
, is n
h re
of filling hole ⇒ page 231 .

hole
spec

es, in part or in w
t to the co
♦ Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.
rrectness of i
♦ With gearbox removed, secure torque converter against falling

out.
l purpos
♦ Thoroughly clean connecting points and surrounding areas

and then loosen bolts.
nform
ercia
♦ Before installing gearbox, check installation dimension for tor‐

m
a
com
que converter ⇒ page 17 .

ion in
r
te o
♦ When installing the gearbox, ensure that dowel sleeves be‐

thi
s
iva
tween the engine and gearbox are correctly located.

do
r
rp
cum
fo
♦ Place removed parts on a clean surface. Cover parts to pre‐

en
ng
t.
yi
vent soiling. Use plastic sheeting and paper. Use lint-free
Co
op py
cloths only! t. C rig
gh ht
pyri by
♦ Install only clean parts; do not remove new parts from pack‐
co Vo
by lksw
cted
aging until immediately before installing.
agen
Prote AG.
♦ If repair work cannot be performed immediately, cover new

parts which have been removed from their packing.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.

6.1.3 Valve body

♦ Renew gearbox if the selector elements are scorched or burnt.
♦ Allocate valve body according to gearbox codes ⇒ Electronic
parts catalogue (ETKA) .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
6.1.4 Gaskets, seals d b ara
rise nte
tho eo
u ra
♦ Always renew O-rings, seals and gaskets.
ss a c
ce
le
un
♦ When seals have been removed, check contact surface on
pt
an
d
housings or shafts for burrs and damage and rectify as nec‐

itte
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erm
essary.
ab
ility
ot p
♦ Thoroughly clean housing connecting surfaces and apply
wit
is n
sealant - AMV 188 200 03- .
h re
ole,
spec
♦ Before installing a radial oil seal, half fill space between sealing
lips with grease - G 052 128 A1- -arrow- and then install.
t to the co
♦ Open side of oil seal faces oil.
rrectne
♦ Before installing oil seals, moisten outer circumference of seal
and sealing lip with ATF or gear oil depending on installation
location.
ss o
cial p
f
♦ Moisten O-rings with ATF to prevent damage to the rings dur‐
inform
ing assembly.
mer
atio
♦ Only use ATF for automatic transmission components. Other
om
n
types of lubrication cause faults to occur in the gearbox hy‐
c
i
or
n
draulics.
thi
te
sd
iva
o
r
♦ After installing, check ATF level in planetary gearbox or gear

p
cum
r
fo
oil in final drive and correct level if necessary.

en
ng
t.
yi Co
op
– ATF in planetary gearbox ⇒ page 151 . C py
t. rig
gh ht
yri by
– Gear oil in front final drive ⇒ page 275 . cop Vo
by lksw
cted agen
Prote
– Gear oil in transfer box ⇒ page 298 .
AG.
– Gearbox oil in rear final drive ⇒ page 8 .

6.1.5 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch circlips. Replace as necessary.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
6. General repair notes 11

AG. Volkswagen AG d
6.1.6 Nuts and bolts Volksw
agen oes
not
gu
by ara
d
♦ Loosen and tighten securing bolts and nuts
orise for covers and nte
eo
housings diagonally. auth
ra
ss c
♦ Do not cant particularly sensitive parts such as the valve body.
ce
le
un
pt
Loosen and tighten nuts and bolts gradually and in diagonal
an
d
itte
sequence.
y li
rm
ab
pe
ility
♦ Specified torques settings are specified for unoiled bolts and ot
wit
nuts.
, is n
h re
hole
♦ Threads of bolts secured with locking fluid must be cleaned
spec
with a wire brush. Then insert bolts with locking fluid -
es, in part or in w
t to the co
AMV 185 100 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
rrectness of i
Otherwise there is a danger of bolts shearing when subse‐
l purpos
quently being removed.

♦ Always renew self-locking bolts and nuts.
nform
ercia
♦ Ensure with threaded connections that contact surfaces as

m
well as nuts and bolts are rewaxed only after assembly, if nec‐
a
com
tio
essary.
n in
r
te o
thi
s
iva
6.1.7 Bearings
do
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cum
fo
en
g
♦ Tapered roller bearings are allocated in ⇒ Electronic parts

n
t.
yi Co
catalogue (ETKA) according to gearbox date of manufacture Cop py
t. rig
and codes. opyri
gh by
Vo
ht
c lksw
♦ All tapered roller bearings fitted to the same shaft must be re‐
by
cted agen
Prote
newed as a set. Use same make of bearings.
AG.
♦ Install needle bearings with lettered side (thicker metal) to‐

wards fitting tool.
♦ Heat tapered roller bearing inner races to approx. 100 °C be‐
fore installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
♦ Depending on location, apply gear oil or ATF to bearings be‐
fore installing.
6.1.8 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.

6.1.9 Guided fault finding, vehicle self-diag‐

nosis and testing
♦ Before performing repairs on the automatic gearbox, deter‐
mine the cause of the fault as accurately as possible using
vehicle diagnosis, testing and information system - VAS 5051-
in modes of operation “guided fault finding”, “vehicle self-
diagnosis” and “test instruments”.
6.1.10 Gear wheels

Before pressing on, clean and heat on a hotplate to maximum
100° C. gen AG
. Volkswagen AG
d wa oes
olks no
The temperature candbe by checked with thermometer -
V t gu
ar
V.A.G 1558- , ignition
ir se tester - V.A.G 1767- or diesel tester -ante
ho eo
V.A.G 1743- . aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
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hole
6.2 »Vorsprung durch Technik«

spec
es, in part or in w
t to the co
The gearbox “01V” can be repaired. The instructions for repair

were written by Audi and are being used by Volkswagen.
♦ »General« data and information for fault finding can be found
rrectness of i
in ⇒ Automatic gearbox 01V, Front and four-wheel drive; Rep.

l purpos
gr. 00
♦ Instructions for the torque converter ⇒ Automatic gearbox
nf
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01V, Front and four-wheel drive; Rep. gr. 32

orm
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♦ Planetary gearbox ⇒ Automatic gearbox 01V, Front-wheel

atio
m
drive and four-wheel drive; Rep. gr. 37

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♦ »Gears, control« ⇒ Automatic gearbox 01V, Front-wheel drive

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and four-wheel drive; Rep. gr. 38

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6. General repair notes 13

32 – Torque converter
1 Torque converter
1.1 Assembly overview - torque converter
1 - Torque converter
❑ Secure in place when
gearbox is removed
⇒ page 14
❑ Identification
⇒ page 15
❑ Installing ⇒ page 17
2 - Seal
❑ Renewing ⇒ page 16
3 - Stop ring
❑ Behind oil seal
❑ Renew if damaged
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Secure torque converter to prevent it from falling out

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14 Rep. gr.32 - Torque converter

1.2 Identification of torque converter

There are various torque converters. They are identified by codes.
Allocation of torque converter to gearbox ⇒ page 3 .
1.3 Checking torque converter

– Check torque converter hub for scoring.
The torque converter is welded and must be renewed if damaged.
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1.4 Draining torque converter
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Special tools and workshop equipment required
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♦ Oil extraction unit - V.A.G 1358 A-
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♦ Oil extraction probe - V.A.G 1358 A/1-
t to the co
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If ATF has become fouled by abraded material or if a major over‐

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1. Torque converter 15
– Extract ATF from torque converter using oil extractor -

V.A.G 1358 A- and oil extraction probe - V.A.G 1358 A/1-
1.5 Removing and installing torque convert‐

er oil seal
1.5.1 Removing
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♦ Oil seal extractor lever - VW 681-
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♦ Thrust piece - 3295-

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– Remove gearbox ⇒ page 64 . cted agen
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– Secure gearbox to assembly stand ⇒ page 142 .

– Apply oil seal extractor lever - VW 681- directly behind sealing

lip of oil seal to avoid damaging stop ring.
1.5.2 Installing
– Insert stop ring.
swage es n
– Apply ATF to circumference
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and sealing lips of ot oil
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Installation position:
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Open side of oil seal faces gearbox.
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– Using thrust piece - 3295- , drive in torque converter oil seal
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to stop of thrust piece.

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– Installing gearbox ⇒ page 64 .
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1.6 Installing torque converter

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♦ Depth gauge
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– Push on torque converter hub through seal to first stop.

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– Turn torque converter inwards using light pressure until notch

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1. Torque converter 17
The torque converter is correctly installed when the distance be‐

tween the contact surfaces underneath at the threaded holes for
the torque converter and the contact surface of the torque con‐
verter housing of the automatic gearbox four-wheel drive 01V is
approx. 23 mm.
If the torque converter is not installed correctly the distance is
approx. 11 mm.
WARNING
If the torque converter is improperly installed, the follower of

the converter or ATF pump will be destroyed when the gearbox
is bolted onto the engine.
During subsequent installation, observe in particular the following

points:
When tightening bolts on engine/gearbox flange, check repeat‐
edly that the torque converter can still be turned behind the drive
plate.
If the torque converter cannot be turned, it can be assumed that
it is not properly installed and that the follower of the torque con‐
verter or the ATF pump will be destroyed during the final tighten‐
ing of the screw connections.
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37 – Controls, housing
1 Connecting -VAS 5051- and select‐
ing functions
1.1 Connecting tester

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♦ Vehicle diagnosis,
db testing and information system
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♦ Diagnosis cable, 3 m with voltage supply - VAS 5051/1- or rrectness of i
diagnosis cable, 5 m without voltage supply - VAS 5051/3-
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WARNING
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♦ During a road test, always secure testing and measuring

com
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equipment on the back seat.

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

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– Remove cover above diagnostic connection on right next to
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handbrake lever.
– Push connector of diagnosis cable - VAS 5051/1- or -
VAS 5051/3- onto diagnosis connection.
1. Connecting VAS 5051 and selecting functions 19

1.1.2 Vehicles from 10.00

– Push connector of diagnosis cable - VAS 5051/1- or -
VAS 5051/3- onto diagnosis connection.
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1.1.3 Continuation for all vehicles
All functions which were previously performed with the -
rrectness of i
V.A.G 1551- can also be performed with the new tester -
VAS 5051- in the mode “vehicle self-diagnosis” ⇒ operating
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manual for vehicle diagnosis, testing and information system

VAS 5051 .
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– Switch on tester -arrow-.
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The tester is ready for operation when the button fields display
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– Switch on ignition.
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♦ Model year
♦ Version
♦ Engine code
– Confirm data entered.
Note
Wait until tester has read all control units in vehicle.
– Press Go to button and select “Function/component selec‐

tion” function.
Now follow information given on screen to start desired functions.
20 Rep. gr.37 - Controls, housing

2 Electrical and electronic components and their locations

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1 - Control unit for automatic yV
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gearbox - J217- ir se
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❑ Location ⇒ page 22 auth or
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❑ Removing ⇒ page 22
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❑ Can be checked using rm
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2 - Engine control unit
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❑ Location and removing
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and installing
⇒ page 23
3 - Diagnostic connection
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❑ Location in vehicles be‐
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fore 09.00 ⇒ page 23 .

❑ Location in vehicles af‐
nform
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ter 10.00 ⇒ page 23 .

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4 - Wiring harness with gear‐
com
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box oil temperature sender
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(ATF) - G93-
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❑ Location ⇒ page 24
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❑ Can be checked using
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VAS 5051-
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5 - Valve body cop Vo
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❑ With hydraulic control

type E17 or E18/2
❑ Components can be
checked using “guided
fault finding” of -
VAS 5051-
6 - Multifunction switch - F125-
❑ Removing and installing ⇒ page 197 .
❑ Can be checked using “guided fault finding” of -VAS 5051-
7 - Gearbox input speed sender - G182-
❑ Measures gearbox input shaft speed
8 - Gearbox speed sender - G38- or gearbox output speed sender - G195-
❑ Measures gearbox output shaft speed
9 - Tiptronic switch - F189-
❑ If the switch is faulty, the symbol panel with printed circuit board must be replaced
⇒ Item 7 (page 39)
2. Electrical and electronic components and their locations 21

10 - Selector lever lock solenoid - N110-

11 - Throttle valve potentiometer - G69- or accelerator pedal position senders - G79- and -G185-
❑ More information ⇒ page 27 .
12 - Cruise control system switch - E45-
13 - Starter inhibitor relay - J207-
14 - Selector lever position display - Y6-
❑ If all segments of selector lever position indicator light up together or
❑ If no selector lever position is displayed, this indicates gearbox emergency running mode
15 - Kickdown switch - F8-
❑ Location in vehicles without EPC ⇒ page 26
❑ Location in vehicles with EPC ⇒ page 26
16 - Brake light switch - F- or brake pedal switch - F47-
❑ Location and removing and installing ⇒ page 26
Location of control unit for automatic gearbox - J217-

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Removing automatic gearbox control unit - J217-

es, in part or in w
t to the co
– Remove right lower A-pillar trim and right sill panel trim ⇒
General body repairs, interior; Rep. gr. 70 ; Pillar and side
trims; Removing and installing lower A pillar trim .
rrectness of i
– Loosen and raise carpet.

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– Unclip control unit from box -arrows-.

nform
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– Switch off ignition and then wait 30 seconds before removing

multi-pin connector.
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– Release multi-pin connector and then pull connector off con‐

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Rep. gr.37 - Controls, housing
Installing automatic gearbox control unit - J217-

– Place multi-pin connector on gearbox control unit connector
housing -1-, swing in -2- and lock -3-.
If the control unit has been replaced, it must be coded. To do this:
– Connect -VAS 5051- and advance through program until
“Function/component selection” is displayed ⇒ page 19 .
– Then press “Drive (Rep. Gr. 01; 10...26; 28...39)”.
– Then “5-speed automatic gearbox 01V”.
– Press “01 - Self-diagnosis”.
– Press “Electrical components”.
– Press “J217 - Automatic gearbox control unit”.
– Press “Code control unit”.
Engine control unit

Location: the control unit is located in left plenum chamber.
Removing and installing control unit:
⇒ Rep. gr. 23 ; of the corresponding engine code letters
⇒ Rep. gr. 24 ; of the respective engine codes
If engine control unit or gearbox control unit is renewed, the sys‐
tem must be restored to basic setting.
– Perform the basic setting in “Vehicle self-diagnosis” with the -
VAS 5051- .
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Location: diagnostic connection is located in centre console.
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– Removes au cover above diagnostic connection next to handbrake
ra
c
s
lever.
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Diagnostic connection in vehicles after 10.00

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Location: Diagnosis connection is located below driver storage

compartment.
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Valve body
Location: valve body is bolted to underside of gearbox housing
and covered by pan.
Solenoid valves - N88- , -N89- , -N90- , -N91- , -N92- , -N93- , -
N94- are secured to the valve body of hydraulic control E17.
On the valve body of hydraulic control E18/2, solenoid valves -
N91- , -N92- , -N93- and -N94- are designated pressure control
valves 1 - N215- , 2 -N216- , 3 -N217- and 4 -N218- .
There are two different types of hydraulic control:
♦ Gearbox with hydraulic control E17, in which the gearbox input
speed sender (inductive sender) is secured to the underside
of the valve body.
Removing and installing valve body ⇒ page 173 .
Information about which control is installed ⇒ page 3 .
♦ Gearbox with hydraulic control E18/2, in which the gearbox
input speed sender (Hall sender) is secured to the gearbox
housing behind the valve body.
Removing and installing valve body ⇒ page 173 .
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Wiring harness with integral gearbox oil temperature sender
ut
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(ATF) - G93- ss a c
ce
le
Location: Gearbox oil temperature sender is located in wiring har‐

un
pt
an
d
ness on valve body.

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Valve body must be removed to replace wiring harness. It is not
pe
ility
ot
necessary to remove gearbox.
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Removing and installing wiring harness ⇒ page 191 .
hole
spec
es, in part or in w
t to the co
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Gearbox speed sender - G38- or gearbox output speed sender -
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G195-
Location: Gearbox speed sender is located on rear right of gear‐
nform
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box.
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Removing and installing gearbox speed sender ⇒ page 188 .

tion in
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5-speed automatic gearbox e o four-wheel drive 01V - Edition 04.2013
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Multifunction switch - F125-
un
pt
an
d
itte
Location: multifunction switch -1- is located on left of gearbox;
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multi-pin connector for multifunction switch -2-.
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Vehicles through 09.00
is n
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ole,
Multi-pin connector for 8-pin multifunction switch.
spec
Vehicles from 10.00
t to the co
Multi-pin connector for 10-pin multifunction switch.
rrectne
Removing and installing multifunction switch ⇒ page 197 .
ss o
cial p
Gearbox input speed sender - G182-
f inform
mer
atio
om
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Location: The gearbox input speed sender is located on the un‐

derside of the valve body on gearboxes with hydraulic control
E17. In these gearboxes, the sender is an inductive sender.
In gearboxes with hydraulic control E18/2, gearbox input speed
sender -A- is secured to the gearbox housing behind the valve
body. In these gearboxes, the sender is a Hall sender.
Removing and installing gearbox input speed sender
⇒ page 189 .
Selector lever lock solenoid - N110-

Location: Selector lever lock solenoid is located in mounting
bracket of selector mechanism.
Removing and installing selector lever lock solenoid
⇒ page 49 .

Cruise control system switch - E45-

Location: cruise control switch is located on steering column
switch.
Removing and installing cruise control system switch ⇒ Electrical
system; Rep. gr. 94 ; Steering column switch, Removing and in‐
stalling steering column switch .
Kickdown switch - F8- in vehicles without EPC

Location: Kickdown switch -arrow- is integrated into accelerator
cable and is located on bulkhead in engine compartment.
Removing and installing kickdown switch ⇒ Rep. gr. 20 ; Re‐
moving and installing parts of fuel supply; Adjusting accelerator
cable .
– When removing and installing kickdown switch, accelerator
cable must be removed and later installed and adjusted.
Kickdown switch - F8- in vehicles with EPC

Location: The kickdown switch is integrated in accelerator posi‐
tion sender.
Removing and installing kickdown switch: Repairing accelerator
mechanism ⇒ Rep. gr. 20 ; Removing and installing parts of fuel
system; Repairing accelerator mechanism .
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Brake light switch - F- or brake pedal switch - F47- y li

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Location: switch is located on the pedal cluster.
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Removing and installing brake light switch or brake pedal switch

h re
hole
⇒ Brake systems; Rep. gr. 46 ; Assembly overview - Brake pedal

spec
(RHD); Adjusting brake light switch and brake pedal switch F47
es, in part or in w
t to the co
rrectness of i
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Starter inhibitor relay - J207-

Location: relay is located on the relay plate on left behind dash
panel.
Relay is identified with the number “204”.
Assignment ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Removing and installing dash panel trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel; Removing and installing dash
panel .
Selector lever position display - Y6-

Vehicles through 09.00
Location: in dash panel insert
Vehicles from 10.00
Location: in dash panel insert with data bus diagnostic interface
- J533-
Removing and installing selector lever position display ⇒ Elec‐
trical system; Rep. gr. 90 ; Dash panel insert; Removing and
installing dash panel insert
Throttle valve potentiometer - G69- or accelerator pedal position

senders - G79- and -G185-
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addition, the data bus interfaceed byin these vehicles must be ara
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checked. thoris
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If the electrical signalsss in the “vehicle self-diagnosis” for gearbox c
ce
le
ECU are displayed as faults, then the “self-diagnosis” for engine

un
pt
ECU must always be performed.

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If the throttle valve potentiometer or accelerator pedal position

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sender has been renewed or its setting changed, “basic setting”

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of the engine control unit must also be performed.

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spec
Locations:
t to the co
The potentiometer is part of the throttle valve module - J338- . It

is located on the throttle valve housing on the engine's intake
manifold.
rrectne
Checking and adjusting or removing and installing throttle valve

potentiometer ⇒ Rep. gr. 23 ; of the respective engine codes .
ss o
cial p
The accelerator pedal position sender - G79- , a component of

inform
the electronic power control (EPC), is located on the pedal cluster.

mer
atio
m
Checking or removing and installing the accelerator pedal posi‐

o
n
c
tion sender ⇒ Rep. gr. 20 ; Removing and installing parts of the

i
or
n thi
e
fuel supply; Checking accelerator position sender .

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5-speed automatic gearbox four-wheel drive 01V - Editiond 04.2013
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Tiptronic switch - F189- au ra
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Location: The Tiptronic switch - F189- is integrated in the printed
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circuit board of the symbol panel, which is located in the selector
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mechanism cover.
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It consists of 3 Hall sensors -A-, -B- and -C-, which are activated
by a magnet on the roller blind of the cover strip.
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-B- Sensor for Tiptronic detection
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3 Repairing selector mechanism
WARNING
Before working on vehicle with engine running, move selector

lever into position “P” and apply handbrake.
3.1 Checking selector mechanism

It should not be possible to operate the starter while the selector
lever is in position “2”, “3”, “4”, “D” or “R”
On right-hand drive vehicles, the starter must operate in selector
lever positions “P” and “N” only when the button in the selector
lever handle is not pressed.
When selector lever is shifted to position “N” at speeds above 5
km/h, solenoid for selector lever lock must not engage and block
selector lever. Selector lever can be shifted into a driving gear.
When the vehicle is moving at speeds below 5 km/h (almost sta‐
tionary) and the selector n Alever
G. Volkis
swshifted
agen AG to position “N”, the sole‐
noid for selector lk swagelock should only engage
lever
does
not after about 1
Vo
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ed by lever cannot be shifted out of g“N”
ua position until
ran
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3.1.1 Selector lever in “P” position and ignition
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switched on
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• Brake pedal not depressed:

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Selector lever is locked and cannot be shifted out of “P” position

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when the button is pressed. Solenoid for selector lever lock blocks
hole
spec
selector lever.
es, in part or in w
t to the co
• Brake pedal depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
rrectness of i
“P” to “2”, checking whether selector lever position in dash panel

insert corresponds to selector lever position.
l purpos
3.1.2 Selector lever in “N” position and ignition

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• Brake pedal not depressed:

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Selector lever is locked and cannot be shifted out of “N” position

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• Brake pedal depressed:
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sible to shift into a driving gear.
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3.1.3 Selector lever in position “D”, ignition

and lights switched on
• Shift selector lever into Tiptronic gate.
The illuminated “D” symbol in the selector lever position display
must go out and the “+” and “-” symbols must light up.
When selector lever is shifted into Tiptronic gate, selector lever
position display in dash panel insert must change from “P R N D
4 3 2” to “5 4 3 2 1”.
3. Repairing selector mechanism 29

AG. Volkswagen AG d
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3.1.4 Selector lever position display d byV
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Simultaneous illumination of all selector lever position
ut
h display
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segments indicates that the gearbox is in gearboxss a emergency c
running mode.
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– Check and adjust selector lever cable ⇒ page 30 .
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– Check ignition key withdrawal lock ⇒ page 33 .
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3.2 Checking and adjusting selector lever
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hole
cable
spec
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3.2.1 Checking
rrectness of i
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♦ Removal lever - 80-200-
nform
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♦ Torque wrench - V.A.G 1331-
Additional required information

♦ Workshop manual Passat 1997 ► Engine, mechanics
– Move selector lever to “P” position.
– Raise vehicle.

– In vehicles with an auxiliary heater, remove bolts -arrows- from

exhaust pipe to the insulation.
– Remove noise insulation -arrows A and B-.

– In vehicles with noise insulation -D-, remove bolts
-arrows C-.
AG. Volkswagen AG d
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3.2.2 Vehicles with V6 and W8 engine au ra
ss c
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– Remove front exhaust system with catalytic converter ⇒ Rep.
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gr. 26 ; Removing and installing parts of exhaust system .
y li
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ility
– Remove bolts -1- and -4- and selector lever cable guard plate
ot p
-A-.
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spec
es, in part or in w
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– Remove left gearbox support ⇒ page 144 .

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– Remove selector lever cable from selector shaft lever

-arrow-.
– Move selector lever from “P” to “2”.
• Selector lever mechanism and selector lever cable must move
freely. Renew selector lever cable or repair selector lever
mechanism as necessary.
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in parking lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
tion).
• It must be possible to press the selector lever cable onto the
selector shaft lever. If this is not possible, adjust the selector
lever cable.
– Carefully press selector lever cable onto selector shaft. Vlever
using pliers, taking care not to bend selectorksshaftn AG olkswagen AG do
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cause otherwise it will not be possible tobyprecisely
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selector mechanism. rised ran
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3.2.4 Adjusting
s
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• Selector lever cable is disconnected from selector shaft lever.
itte
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es, in part or in w
tion).
t to the co
– Loosen bolts -arrows 1- securing support bracket to gearbox.
rrectness of i
– If necessary, detach selector lever cable from support bracket
-arrow 2-. When doing this, counterhold on hexagon flats
l purpos
-arrow 3-.
– Lubricate ball socket of selector lever cable with polycarba‐
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mide grease - G 052 142 A2- .

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– Using a pair of pliers, carefully push selector lever cable onto

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selector shaft lever -2-.

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– Align selector lever cable, free of stress, on the support brack‐
et using the oblong holes.

– Tighten support bracket on gearbox -arrows 1- to specified

torque ⇒ page 53 .
Volkswagen AG
– Tighten support bracket for selector lever cable -arrow a2-
gento
AG. does
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specified torque ⇒ page 53 . When doing this, counterhold
by
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on hexagon flats -arrow 3-. ris
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– Check selector mechanism ⇒ page 29 s.s au ra
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– Installing left gearbox support ⇒ page 144 .
nl
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3.2.5 Vehicles with V6 and W8 engine
es, in part or in w
t to the co
– Install selector lever cable guard plate ⇒ page 53 .
– Install front exhaust system with catalytic converter ⇒ Rep.
rrectness of i
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– Install noise insulation element(s).
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– In vehicles with an auxiliary heater, bolt exhaust pipe firmly to
atio
m
noise insulation.
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3.3 Checking operation of the ignition key withdrawal lock
Start
↓ ← ← ← ← ← ← ← ← ← ← ← ← ←
↓ ↑
– Shift selector lever to “P”. – Renew faulty selector mechanism or steer‐
ing lock.
– Switch off ignition and remove ignition key.
↓ ↑
↓ no → → → ↑
↓ ↑
Can selector lever be shifted out → yes → Is locking cable → yes → – Correct adjust‐
of “P” with button pressed? not adjusted cor‐ ment
rectly? ⇒ page 57 .
↓ ↑
no ↑ ← ← ←
↓ ↑
Function OK. ↑
↓ ↑
– Press brake pedal. ↑
– Insert ignition key and switch on ignition.
– Shift selector lever to “P”.

↓ ↑
Can selector lever be shifted out of “P” with → no → → ↑
button pressed?
↓ ↑
yes ↑
↓ ↑
It must be possible to move selector lever into “R, N, ↑
D, 4, 3, 2”.
↓ ↑
– Switch off ignition. ↑
– Release brake pedal.

↓ ↑
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Can ignition key be withdrawn? olks wa → → doe syes
not → ↑ ← no
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→ tho →
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no – Presssa
u brake pedal and shift selec‐ The ignition key
r ac can be removed and the button
tors lever to “P”. on the selector lever is blocked in “P”.
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Ignition key withdrawal lock OK.
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spec
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3.4 Removing and installing selector lever
rrectness of i
handle
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3.4.1 There are various handles which are re‐

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moved and installed in different ways.

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– Before every assembly work, push down sleeve on selector

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lever slightly.
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– Check colour of plastic part in handle.

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Colour is black: removing and installing ⇒ page 35 .
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3.4.2 Removing and installing handle with

reddish brown plastic part
– Simply pull handle only. Do not press button as you do so.
If you inadvertently press the button into the handle, you can ei‐
ther pull it out again or carefully blow it out with compressed air.

– It is essential to make sure before installing that the push but‐

ton is pulled out at least 10 mm -a- past the pressure point. gen AG. Volkswagen AG
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Do this by pulling the button out by hand past the palpable
db
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sure point so that it will not drop back again. or
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– For installation, move selector lever to “D” and
ss press handle
a c
onto selector lever.
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3.4.3 Removing handle with black plastic part
– Set selector lever in position “3”.
rrectne
– Slide sleeve -1- downwards.
s
– Pull button -2- out of handle -3- just enough so that pull lever
s o
-arrow- hangs downwards.
cial p
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– Now pull handle off selector lever.
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3.4.4 Installing handle with black plastic part

– Set selector lever in position “3”.
– Pull button -2- out of handle -3- just enough so that pull lever
-arrow- hangs downwards.
Installation position: Button faces driver.
– Now press the handle on selector lever onto stop.
– Pull pushbutton out further and guide pull lever -arrow- into
handle.
– Press pushbutton so that pull lever engages in pull rod -4-. The
button must now spring back onto stop.
– Slide the sleeve -1- upwards.
– Set selector lever in position “P”.

Passat 1997 ➤ , Passat Variant 1997 ➤ AG. Volkswagen AG d
agen
5-speed automatic gearbox four-wheel drive 01V - EditionVo04.2013
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3.5 Removing and installing selector mech‐
r
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anism ss c
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♦ Workshop manual Passat 1997 ► General body repairs, inte‐
h re
rior
hole
spec
es, in part or in w
3.5.1 Removing
t to the co
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
rrectness of i
– Move selector lever to “P” position. l purpos
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
nf
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connecting battery .
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– Remove selector lever handle ⇒ page 34 .
om
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or c
– Remove centre console and extension ⇒ General body re‐
thi
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pairs, interior; Rep. gr. 70 ; Compartments, covers and trims;
sd
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Removing and installing centre console .

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– Remove cover ⇒ page 60 .

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– Unplug electrical connectors ⇒ page 42 .
rig
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– Unclip locking cable from locking lever and unclip securing
lksw
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spring on mounting bracket. To do this, lift securing spring
AG.
slightly.
– Raise vehicle.
– Remove front exhaust system with catalytic converter if nec‐
essary ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
– Unbolt propshaft from gearbox, raise it and tie or support
⇒ page 201 .
– Remove cover from mounting bracket -arrows-.
– Press together ends of securing clip -B- and remove.

– Pull out securing plate -A- for selector lever cable on mounting
bracket downwards.
– Pull selector lever cable off selector lever.
– Remove nuts (Qty. 4) from above.
– Remove mounting bracket downwards.
– Simultaneously pull selector lever cable out of mounting
bracket, taking care not to kink selector lever cable.

3.5.2 Installing
• Selector lever and selector shaft lever in position “P” (parking
lock must engage).
– Raise vehicle.
tion).
– Slide selector lever cable boot and mounting bracket cover
onto selector lever cable.
– Do not bend or kink selector lever cable.
– Insert selector lever cable in mounting bracket.
– Install mounting bracket on body.
– Tighten nuts (Qty. 4) from above ⇒ Item 21 (page 40) .
– Connect electrical connections ⇒ page 42 .
– Install and adjust locking cable ⇒ page 54 .
AG. Volkswagen AG d
– Install cover ⇒ page 60 . agen oes
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– Move selector lever torisposition
ed “3”. nte
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– Install selector lever
ss a handle ⇒ page 34 .
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– Connect selector lever cable to selector lever. ab

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The angled end of the locking plate -A- must point towards the
spec
end of the selector lever cable.

es, in part or in w
t to the co
– Fit locking plate -A- for selector lever cable onto mounting
bracket.
rrectness of i
– Press together ends of securing clip -B- and slide onto end of
selector lever cable.
l purpos
– Install cover. When doing this, check position of seal.

nf
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– Tighten nuts -arrows- ⇒ Item 28 (page 41) .

– Check selector lever cable adjustment and adjust if necessary
⇒ page 30 .
– Connect propshaft ⇒ page 201 .
– Install front exhaust system with catalytic converter if it was
removed ⇒ Rep. gr. 26 ; Removing and installing parts of
exhaust system .
– Install centre console and extension ⇒ General body repairs,
interior; Rep. gr. 70 ; Compartments, covers and trims; Re‐
moving and installing centre console .
– Connect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; gen AG
. Volkswagen AG
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Battery; Disconnecting and connecting battery . yV
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– Check selector mechanism ⇒ page 29 . thoris
eo
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s a ; Ra‐
– Code radio ⇒ Radio, telephone, navigation; Rep. gr. s91 c
ce
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dio, telephone, navigation .
nl
pt
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itte
– Initialise electric windows and set clock ⇒ Maintenance ; Book‐
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let 36 .
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3.6 Assembly overview - dismantling and
h re
hole
spec
assembling selector mechanism
es, in part or in w
t to the co
Procedure for dismantling and assembling ⇒ page 43 .
rrectness of i
♦ Polycarbamide grease - G 052 142 A2-
l purpos
Lubricate bearing positions and sliding surfaces with polycarba‐

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1 - Selector lever handle

❑ Removing and installing
⇒ page 34 .
2 - Sleeve
❑ Engages in selector lev‐
er handle.
❑ Prevents selector lever
handle from being
pulled off
❑ Installation position: an‐
gled surface faces to‐
nAG. Volkswagen AG d
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3 - Cover rised nte
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❑ sWith
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s ⇒ Item 6 (page 39) ,
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symbol panel
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⇒ Item 7 (page 39) ,
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and guide
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spec
❑ Remove upwards.
es, in part or in w
t to the co
❑ Removing connector for
selector positions, se‐
lector lever lock and Tip‐
tronic ⇒ page 42
rrectness of i

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⇒ page 60
❑ Dismantling and assem‐
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bling ⇒ page 59
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4 - Guide sleeve
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❑ Slide onto selector lever

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❑ Installation position: En‐

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gage foot to rear

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5 - Cover moulding C py
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❑ With trim piece ⇒ Item 6 (page 39) and symbol panel ⇒ Item 7 (page 39)
py by
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❑ Cannot be renewed individually
cted agen
Prote AG.
❑ Removing and installing ⇒ page 59
6 - Trim piece
❑ Integrated with symbol panel ⇒ Item 7 (page 39) in cover moulding ⇒ Item 5 (page 39)
7 - Symbol panel
❑ With printed circuit board
❑ With Tiptronic switch - F189- integrated in the printed circuit board
❑ Integrated with trim piece ⇒ Item 6 (page 39) in cover moulding ⇒ Item 5 (page 39)
8 - Cover strip
❑ With 2 magnets for Tiptronic switch - F189- and gear indicator
❑ Magnets must be firmly attached to cover strip
❑ Secure in mounting bracket ⇒ Item 22 (page 40) with locking plate ⇒ Item 11 (page 40)
9 - Guide
❑ Guides cover strip
❑ Release from cover moulding ⇒ Item 5 (page 39) ⇒ page 60

10 - Bearing bush
❑ Secure in mounting bracket ⇒ Item 22 (page 40) with locking plate ⇒ Item 11 (page 40)
11 - Securing clip
❑ Secures mounting bush ⇒ Item 10 (page 40) in mounting bracket ⇒ Item 22 (page 40)
❑ Install with angled ends pointing towards inside of mounting bracket
❑ Always renew.
12 - Pull rod
13 - Compression spring
14 - Selector lever
❑ With pull rod, coil spring, selector guide and Tiptronic spring mechanism
❑ Dismantling and assembling ⇒ page 47
15 - Bump stop
❑ Clip into cable lever ⇒ Item 17 (page 40)
❑ Install with large contact surface towards selector lever
16 - Detent
❑ Clip into cable lever ⇒ Item 17 (page 40)
17 - Cable lever
❑ Secured in mounting bracket ⇒ Item 22 (page 40) with pivot pin ⇒ Item 23 (page 40)
18 - Detent spring with roller
❑ For selector positions
. Volkswagen AG
❑ Removing and installing ⇒ page gen AG
wa43 does
olks no
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19 - Detent spring with rollerrised nte
❑ For Tiptronic position tho eo
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20 - Frame
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❑ Clip onto mounting bracket ⇒ Item 22 (page 40)

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❑ Installation position: Ribbed side upwards

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21 - Nut, 10 Nm
hole
spec
es, in part or in w
22 - Mounting bracket
t to the co

23 - Pivot pin
rrectness of i
❑ Secures cable lever ⇒ Item 17 (page 40) in mounting bracket ⇒ Item 22 (page 40)
l purpos
24 - Locking pawl
❑ For selector lever lock
nform
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25 - Selector lever lock solenoid - N110-

on in
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❑ Removing and installing cable for selector lever lock ⇒ page 42

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26 - Pivot pin C py
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❑ For locking pawl ⇒ Item 24 (page 40) p by
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Prote AG.

27 - Cover
❑ With seal for mounting bracket ⇒ Item 22 (page 40)
28 - Nut, 10 Nm
29 - Securing clip
❑ For selector lever cable ⇒ Item 31 (page 41) to cable lever ⇒ Item 17 (page 40)
❑ Installation position: Angled end forwards and upwards
30 - Securing clip
❑ For securing selector lever cable ⇒ Item 31 (page 41) to mounting bracket ⇒ Item 22 (page 40)
❑ Installation position: Angled end points to end of selector lever cable
❑ Always renew.
31 - Selector lever cable
❑ Do not bend or kink; lightly grease cable eye and ball socket before installing
❑ Adjusting ⇒ page 30
❑ Selector lever cable must be replaced if rubber sleeves are damaged
❑ When installing, make sure that rubber sleeve on gearbox side is not twisted
32 - Hexagon bolt, 23 Nm
AG. Volkswagen AG d
agen oes
33 - Support bracket olks
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❑ For selector lever cable to gearbox
ris
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❑ Removing and installing ⇒ sa
upage 50
t ra
c
s
34 - Bracket
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❑ For locking cable
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35 - Cable clip
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❑ For locking cable wit

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36 - Ignition/starter switch spec

es, in part or in w
37 - Locking cable
t to the co
❑ For ignition key removal lock.

❑ Must not be kinked
rrectness of i

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38 - Lever for locking cable
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❑ For ignition key removal lock.

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39 - Securing spring
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❑ For locking cable

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40 - Mounting
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3.6.1 Removing and installing cable for selec‐

tor lever lock, selector lever illumination
and Tiptronic
3.6.2 Removing
AG. Volkswagen AG d
rior kswagen oes
n ol ot g
yV u
– Remove centre console ed and extension ⇒ General body re‐ ran
b a
ris
pairs, interior; Rep. ut
hogr. 70 ; Compartments, covers and trims; tee
or
Removing and installing
ss
a centre console . ac
ce
e
– Unplug connector -1- for selector lever lock magnet -2- (con‐
nl
pt
du
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cealed).
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– Unclip cover -3- and lift up.
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– Pull out connector -4- for selector positions and Tiptronic in
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3.6.3 Installing nform

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– Lift top of spring -arrow B- slightly and pull locking cable out of
mounting bracket.
– Disengage spring -arrow A- from retainer lug -arrow C- and
remove upwards.
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3.7 Dismantling and assembling selector
rrectness of i
mechanism - Assembly sequence
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3.7.1 Dismantling
nform
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a
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♦ Tube - VW 421-
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♦ Tube - VW 423-
♦ Polycarbamide grease - G 052 142 A2-

Lubricate bearing positions and sliding surfaces with polycarba‐

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– Remove selector mechanism ⇒ page 36 .

– First remove stop buffer ⇒ Item 15 (page 40) from cable lever
⇒ Item 17 (page 40) .
– Shift selector lever ⇒ Item 14 (page 40) into Tiptronic position
and then remove frame ⇒ Item 20 (page 40) .
– Move selector lever to position “2”.
– Detach lever for locking cable ⇒ Item 38 (page 41) from mount‐
ing by raising and remove from mounting bracket
⇒ Item 22 (page 40) .
– Shift selector lever to position “D”.
– Carefully lever spring clip for Tiptronic position
⇒ Item 19 (page 40) out of mounting bracket
⇒ Item 22 (page 40) from the outside.
– Pull out locking clips ⇒ Item 11 (page 40) for selector lever
⇒ Item 14 (page 40) mounting bushes ⇒ Item 10 (page 40) .
– Push out selector lever ⇒ Item 14 (page 40) mounting bushes
⇒ Item 10 (page 40) using a screwdriver.
– Remove selector lever ⇒ Item 14 (page 40) as a complete unit.
Dismantle selector lever ⇒ page 47 .

– To remove mounting ⇒ Item 40 (page 41) for selector lever

⇒ Item 14 (page 40) Tiptronic position, release retaining lugs
(Qty. 3) on outside of mounting bracket ⇒ Item 22 (page 40)
and remove mounting ⇒ Item 40 (page 41) inwards.
– Press out pin ⇒ Item 26 (page 40) for locking pawl
⇒ Item 24 (page 40) using a drift. Support mounting bracket
⇒ Item 22 (page 40) with tube - VW 423- when doing this.
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– Lift out selector lever lock solenoid ⇒ Item 25 (page 40) to‐
inform
gether with locking pawl ⇒ Item 24 (page 40) .

mer
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– Carefully lever spring clip ⇒ Item 18 (page 40) for selector lever
om
positions out of mounting bracket ⇒ Item 22 (page 40) from

c
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– Move cable lever ⇒ Item 17 (page 40) to park position.

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bracket ⇒ Item 22 (page 40) .
– Unclip detent ⇒ Item 16 (page 40) from cable lever
⇒ Item 17 (page 40) .

3.7.2 Assembling
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– Clip detent ⇒ Item 16 (page 40) into cable lever

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spec
⇒ Item 16 (page 40) , with opening -arrow- of detent leading,

t to the co
into mounting bracket ⇒ Item 22 (page 40) from above.

– Drive both mounting pins ⇒ Item 23 (page 40) for the cable
lever ⇒ Item 17 (page 40) with detent ⇒ Item 16 (page 40) into
rrectne
mounting bracket ⇒ Item 22 (page 40) to stop. Support mount‐

ing bracket on inside when doing this.
ss o
– Press spring clip with roller ⇒ Item 18 (page 40) for selector
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lever position into its seat in mounting bracket

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⇒ Item 22 (page 40) to stop.

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– Push selector lever lock solenoid ⇒ Item 25 (page 40) together

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with locking pawl ⇒ Item 24 (page 40) into mounting bracket

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⇒ Item 22 (page 40) from above.

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– Carefully drive in pin ⇒ Item 26 (page 40) for locking pawl

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– Press mounting for Tiptronic position ⇒ Item 40 (page 41) into
an
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mounting bracket ⇒ Item 22 (page 40) from inside. Locking
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lugs (Qty. 3) must engage.
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– Insert selector lever ⇒ Item 14 (page 40) as a complete unit
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into mounting bracket ⇒ Item 22 (page 40) .
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– Hook selector lever ⇒ Item 14 (page 40) into cable lever
t to the co
⇒ Item 17 (page 40) at top and bottom.
– Slide the two selector lever ⇒ Item 14 (page 40) mounting
bushes ⇒ Item 10 (page 40) into mounting bracket
rrectness of i
⇒ Item 22 (page 40) , one from front and one from rear.
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– Fit new locking clips ⇒ Item 11 (page 40) to secure mounting

bushes ⇒ Item 10 (page 40) in mounting bracket
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⇒ Item 22 (page 40) so that angled ends of clips point inwards.

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com
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⇒ Item 14 (page 40) is in position “P”, locking lever should
AG.
engage detent ⇒ Item 16 (page 40) , making it impossible to

change gear.
– Move selector lever ⇒ Item 14 (page 40) into Tiptronic position.
– Place frame ⇒ Item 20 (page 40) on mounting bracket
⇒ Item 22 (page 40) (ribbed side upwards) and insert stop
buffer ⇒ Item 15 (page 40) in cable lever
⇒ Item 17 (page 40) .
– Install selector mechanism ⇒ page 37 .
3.7.3 Dismantling and assembling selector

lever
– Remove selector lever ⇒ page 43 .
3.7.4 Dismantling
– Drive out selector lever mounting pin using a drift as shown in
the illustration.
– Lift pull rod and push selector guide out of selector lever to‐
gether with Tiptronic spring mechanism.
– Release tension on compression spring and remove pull rod
and compression spring from selector lever.
– Lever guide cover out on both sides.

– Carefully lever out springs -1- and -2- and thrust pieces (Qty.
3) for Tiptronic springs using a screwdriver -arrow-.
3.7.5 Assembling wage

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– Fit guides -C- onto stop so that narrower epart d by faces pull rod. ua
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– Place compression spring -B- onto pullau rod -A-.
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– Insert pull rod and coil spring in selector lever.
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– Check that pull rod slides freely on the two guides -C- of se‐
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lector lever.
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3.7.6 Assemble Tiptronic spring mechanism
as follows:
l purpos
– Press in a gate cover.
nform
ercia
– Insert a short spring -1- and two long springs-2- with thrust
m
at
pieces (Qty. 3) into the gate by hand.
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– Grease Tiptronic spring mechanism lightly with polycarbonate

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– Press in second gate cover.

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– Lift pull rod -D- and slide selector guide -B- with Tiptronic
spring into selector lever -A-.
– Drive in selector lever mounting pin -C- using a drift
⇒ page 47 .
– To secure pin, make two new punch marks -arrows- offset 90°
to the existing ones.
The mounting pin may have a maximum of only 4 punch marks.
– Install selector lever ⇒ ⇒ page 46 .
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3.8.1 Removing
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– Remove stop buffer -2- from cable lever.
s
– Shift selector lever -1- into Tiptronic position and then remove
frame -3-. s o
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– Detach lever for locking cable -4- from mounting by lifting and
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remove from mounting bracket -5-.

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– Press out pin for locking pawl -6- using a drift.

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– Lift out selector lever lock solenoid -7- together with locking
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– Insert selector lever lock solenoid -7- together with locking
pawl into mounting bracket -5- from above.
– Carefully drive in pin for locking pawl -6-.
– Place lever for locking cable -4- in mounting bracket -5- and
make sure that it can be felt to engage in both mountings.
– Place frame -3- on mounting bracket (ribbed side upwards)
and insert stop buffer -2- into cable lever.


cable
3.9.1 Removing
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-arrows C-.

– Remove front exhaust system with catalytic converter ⇒ Rep.
– Remove selector lever cable guard plate.

– Unbolt propshaft from gearbox, raise it and tie or support
⇒ page 201 .
– Remove cover from mounting bracket -arrows-.
Disconnect selector lever cable from mounting bracket:
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– Press together ends of securing clip -B- and remove.
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– Pull out securing plate -A- for selector lever cable on mounting
bracket downwards. rrectness of i
– Pull selector lever cable off selector lever.

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-arrow-.
– Remove support bracket from gearbox.
– Release selector lever cable from support bracket.
– Pull selector lever cable out of mounting bracket, taking care
not kink selector lever cable. gen AG
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3.9.4 Installing
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– Do not bend or kink selector lever cable. Lightly grease cable
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eye and ball socket before installing.
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– Press selector lever cable -1- fully forwards -arrow-.
es, in part or in w
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– Move selector shaft lever -2- on gearbox in
-direction of arrow- to position “2”.
rrectness of i
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– Carefully press ball head of selector lever cable -1- onto se‐
lector shaft lever.
nform
ercia
Take care not to bend selector shaft lever -2- because otherwise
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it will not be possible to adjust selector mechanism precisely.
com
tion in
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– Move selector shaft lever -2- on gearbox to position “P”. Lock‐

te o
thi
ing lever must engage in parking lock wheel so that both front
s
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– Do not bend or kink selector lever cable. Lightly grease cable C py
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– Using a pair of pliers, carefully push selector lever cable onto cted agen
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selector shaft lever -2-.
Be careful not to bend selector shaft lever when pushing cable on
because otherwise shift mechanism cannot be precisely adjus‐
ted.
– Insert selector lever cable in mounting bracket.
– Connect selector lever cable to selector lever.
Angled end of new locking plate -A- must point towards end of
– Fit new locking plate -A- for selector lever cable onto mounting
bracket.
– Press together ends of securing clip -B- and slide onto end of
– Connect selector lever cable to support bracket hand-tight.
– Bolt support bracket to gearbox (hand-tight).
– Align selector lever cable in support bracket.

– Tighten support bracket on gearbox -arrows 1- to specified

torque ⇒ page 53 .
– Tighten support bracket for selector lever cable -arrow 2- to
specified torque ⇒ page 53 . When doing this, counterhold
on hexagon flats -arrow 3-.
– Tighten nuts -arrows- ⇒ Item 28 (page 41) .

– Check selector lever cable adjustment and adjust
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– Connect propshaft ⇒ page 201
ise .
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– Installing left gearbox support
sa
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– Install selector lever cable guard plate ⇒ page 53 .
rrectne
3.9.6 Continuation for all vehicles ss o

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noise insulation.
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3.9.7 Specified torques

Components Specified torque
Selector lever cable -5- on support bracket 12 Nm
-B-
Support bracket -B-, -2- and -3- on gearbox 23 Nm
Guard plate -A-, -1- and -4- on gearbox 23 Nm

3.10 Removing and installing locking cable
3.10.1 Removing
♦ Setting gauge for locking cable - 3352 A-
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♦ Workshop manual Passat 1997 ► Electrical system
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theft code.
– Remove steering wheel with airbag ⇒ General body repairs,
interior; Rep. gr. 69 ; Airbag; Removing and installing steering
wheel or ⇒ General body repairs, interior; Rep. gr. 69 ; Airbag;
Removing and installing driver side airbag unit .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
– Turn ignition key to ignition on position.

– Release locking clip and pull locking cable -1- out of ignition/
starter switch. wage
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– Remove cover ⇒ page 60 . ed by ara
ris nte
– Unclip locking cable from securing spring on mountingtho bracket eo
au ra
by lifting securing spring slightly ⇒ page 42 . ss c
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pt
– Release locking cable from cable clip -2- and take out.
du
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3.10.2 Installing
ab
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– Route locking cable free of kinks.

– Turn ignition key to ignition on position.
– Fit locking cable to ignition/starter switch.
– Check that locking device -1- engages.
– Secure locking cable to airbag sensor with cable clip -2-.
– Turn ignition/starter switch to locked position (ignition off).

– Hook locking cable into locking lever and clip locking cable
support bracket -3- into securing spring of mounting bracket
⇒ page 42 .
3.11 Adjusting locking cable

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– Loosen bolt -6-.

– It must be possible to move support bracket -3- by hand in
direction of arrow -5-.
– Move steering column down and to rear.
– Push on locking cable adjustment gauge - 3352 A- -4- between
lever for locking cable and locking cable eye.
– To compensate for play, pull support bracket in direction of
arrow -5- to stop and tighten bolt -6- to 10 Nm.
– Remove adjustment gauge.
– Check ignition key withdrawal lock after each adjustment of
locking cable ⇒ page 33 .
– Install steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .

– Install steering wheel with airbag ⇒ General body repairs, in‐

terior; Rep. gr. 69 ; Airbag; Removing and installing steering
wheel or ⇒ General body repairs, interior; Rep. gr. 69 ; Airbag;
Removing and installing driver side airbag unit .
– Install selector lever handle ⇒ page 34 .
– Connect battery earth strap ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
– Code radio ⇒ Radio, telephone, navigation; Rep. gr. 91 ; Ra‐
let 36 .
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4 Removing, dismantling and assem‐

bling selector mechanism cover
4.1 Assembly overview - Dismantling andgeassembling

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Removing and installing selector mechanism cover
ho
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⇒ page 60 . ss
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Dismantling and assembling selector mechanism cover
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⇒ page 61 .
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1 - Cover moulding
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❑ With trim piece and
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a complete item
2 - Cover strip
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❑ With 2 magnets
-arrows- for Tiptronic
ss
switch - F189- and gear
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4. Removing, dismantling and assembling selector mechanism cover 59

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4.2 Removing and installing selector mech‐
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– Pull pull rod up and hold up while moving selector lever to po‐
l purpos
sition “P”.
– Switch off ignition.
nform
ercia
– Remove centre console ⇒ General body repairs, interior; Rep.

m
at
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gr. 70 ; Compartments, covers and trims; Removing and in‐
ion
c
stalling centre console .
in t
or
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– Carefully lever retaining tabs -arrows A- (Qty. 4) off from
do
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-arrows A or B- are damaged.
– Lift off complete cover of selector mechanism.
– Press release -arrow A- on plug -1- and pull it out of cover

-2- in direction of arrow -B-.
4.2.2 Installing
Install in reverse order of removal. During this step, observe the
following:

– Connect plug -1- opposite to direction of arrow -B- to cover

-2- before it is clipped into selector mechanism.
– Carefully place cover on selector mechanism and lock with

retaining tabs -arrows A- (Qty. 4).
The complete cover must be renewed if retaining tabs
-arrows A or B- are damaged.
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 70 ; Compartments, covers and trims; Removing and in‐
stalling centre console .
– Install selector lever handle ⇒ page 34 .
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– Remove cover ⇒ page 60 .

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– Carefully lever off retaining tabs -arrows-.
– Remove cover strip -2- from guide -3-.
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4.3.2 Assembling
– Check whether magnets -arrows- are attached to cover strip
rrectness of i
-2-.
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If not, renew cover strip.

– Insert cover strip -2- into guide -3-.
nform
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– Place guide with cover strip onto cover moulding and carefully
lock together -arrows-.
The complete cover must be renewed if retaining tabs -arrows-
are damaged.
– Install cover ⇒ page 60 .
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5 Removing and installing gearbox

Vehicles with 4-cylinder TDI engine with unit injectors
⇒ page 64
Vehicles with 5-cylinder engines ⇒ page 79
Vehicles with V6 TDI engines ⇒ page 91
Vehicles with V6 petrol engines ⇒ page 108
Vehicles with 8-cylinder engine ⇒ page 124
Transporting automatic gearbox ⇒ page 141
Securing gearbox to assembly stand ⇒ page 142
Removing and installing left and right gearbox support
⇒ page 144
5.1 Removing and installing gearbox for vehicles with 4-cylinder TDI engine
with unit injectors

equipment required
♦ Support bracket - 10-222A-
♦ Rack - 10-222A/1-
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♦ Adjustment plate - 3282/19-

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♦ Support bridge - 30-211 A-
5. Removing and installing gearbox 65

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♦ Workshop manual Passat 1997 ► 4-cylinder diesel engine,
l purpos
mechanics (without intermediate shaft)

♦ Workshop manual Passat 1997 ► Running gear, axles, steer‐
nf
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ing - front and four-wheel drive
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♦ Workshop manual Passat 1997 ► General body repairs, ex‐
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terior
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5.1.1 Removing
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– Pull dipstick -1- out of guide tube.
– Unclip covers for nuts.
– Unscrew and remove nuts -arrows- and remove engine cover.
– Unclip covers for nuts.

– Unscrew and remove nuts -arrows- and remove air filter cover.
– Remove intake hose from intake manifold.

– Unclip connectors -1- and -2- from bracket under coolant res‐
ervoir.
– Remove intake connecting pipe with intake manifold flap and
exhaust gas recirculation valve ⇒ 4-cylinder diesel engine,
mechanics (without intermediate shaft); Rep. gr. 26 ; Exhaust
gas recirculation system; Removing and installing parts of the
exhaust gas recirculation system .
– Remove eye of support device - 2024 A- .
– Insert pin into centre hole
n Aof support
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– Fit supportrisbracket
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– Hook lifting tackle - 2024 A- into spindle of support bracket -

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– Take up weight of engine/gearbox assembly on spindles.
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– Loosen wheel bolts.
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– Raise vehicle.
spec
es, in part or in w
t to the co
– Remove front wheels.
rrectness of i
l purpos
– Unclip retaining clip for coupling rod -1- of vehicle level sender
nform
ercia
- G78- from track control link -2-.

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-arrows C-.
– Remove left and right drive shaft noise insulation from wheel
housing -arrows-.
– Remove front exhaust system with catalytic converter ⇒ 4-
cylinder diesel engine, mechanics (without intermediate
shaft); Rep. gr. 26 ; Removing and installing parts of exhaust
system .
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– Remove left drive shaft guard plate -arrows-.
rised The third bolt is ara
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– Disconnect left and right drive shafts -1- from flanges and tie
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up.
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– Remove noise insulation retainer -1-.

l purpos
– Pull connector -2- off wire for multifunction switch.

– Turn locking lever -3- and unplug connector for gearbox wiring
nform
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harness.
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at
– Cut through cable tie -4-.

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– Disconnect speedometer ed connector -arrow A- from gearbox. nte
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– Place drip tray
ss - V.A.G 1306- underneath.
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– Thoroughly clean area around connection between ATF line
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and gearbox.
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– Remove ATF lines from engine/gearbox assembly -arrows-
l purpos
and tie up.

– Seal ATF lines and gearbox with clean plugs.
nform
ercia
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;

m
Removing and installing starter .
a
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– Unbolt torque converter from drive plate (3 securing bolts).
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Turn crankshaft 13 turn for each bolt. cted agen
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– Remove heat shield -A- from vehicle underbody.

– Remove cover plate -B- -arrows-.
– Disconnect propshaft from gearbox ⇒ page 201 .
– Push propshaft back to stop and tie up.

– Mark position of selector lever cable support bracket on gear‐

box housing in order to reinstall it in same position. Unbolt
support bracket -arrows-.
– Remove side and lower connecting bolts for engine/gearbox.
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– Position engine/gearbox jack - V.A.G 1383 A- with gearbox
support - 3282- under gearbox and align adjusting plate par‐
rrectness of i
allel to gearbox and support gearbox.
l purpos
– Secure gearbox to gearbox support - 3282- using bolt -A-.

– Fill space between gearbox support and sump with washers.
nform
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– Before unbolting engine mounting from subframe, mark loca‐
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– Remove nuts -1- below at left and right on engine mounting.
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– Remove gearbox mounting/subframe securing bolts -2-.
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– Before separating subframe, always use locating pins - 3393-
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on both sides of vehicle to check that at least holes -1- and
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-2- align. , is n
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Hole -3- may be disregarded.
nf
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If this is not the case, perform wheel alignment after tightening
orm
subframe!
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– Unscrew bolts -1- and -2- at rear of subframe on both sides of

vehicle.
– Remove bolts -3- at front of subframe on both sides of vehicle.
– Unscrew and remove bolts -4- (two on each side of vehicle).
– Unhook power steering hose from bracket -arrow-.

When lowering the gearbox, please take care not to damage any
components.
– Now step onto stepladder - VAS 5085- to lower the engine/
gearbox assembly using the spindles.

– Lower engine/gearbox assembly by turning spindles approx 8

turns.
– At the same time, lower engine/gearbox assembly using en‐
gine and gearbox jack - V.A.G 1383 A- with the aid of a second
mechanic.

-arrow-.
– Remove upper engine/gearbox connecting bolts.
– Press gearbox off engine while simultaneously pressing tor‐
que converter out of drive plate.
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– Press torque converter against ATF pump -arrow-.
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– Lower gearbox.
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– Secure the torque converter with support bridge - 30-211 A-

to prevent it from falling down.
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Use workshop hoist - V.A.G 1202 A- and transportation tool -

m
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3457- to transport the automatic gearbox ⇒ page 141 .

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When working on gearbox, secure it to repair stand with transport

thi
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device - 3457- and retaining plate - VW 309- ⇒ page 142 .

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5.1.2 Installing
– Clean ATF cooler and ATF lines before installing an exchange
gearbox ⇒ page 169 .
– Before installing gearbox, ensure that torque converter seats
correctly in gearbox ⇒ page 17 .
– Ensure that the dowel sleeves and the intermediate plate are
correctly positioned on engine.

– Threaded holes in flange shaft behind gearbox must be

cleaned of all locking fluid residue. A thread chaser is suitable
for cleaning.
– Set up gearbox support - 3282- .
Set up gearbox support - 3282- for automatic gearbox 01V with
adjusting plate - 3282/19- .
The symbols on the adjusting plate indicate the mounts required;
– Place gearbox on gearbox jack.
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– Secure gearboxthto gearbox support - 3282- using bolt -A-. tee o
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– Place gearbox jack under vehicle. ss
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– Guide gearbox in between lowered subframe and underbody.
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– Align gearbox to engine.
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– Bolt torque converter and drive plate together.
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To do this, screw in the bolts by hand and tighten to 85 Nm. rrectness
– A bracket or an earth connection is bolted onto some con‐

o
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necting bolts ⇒ page 79 .

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– Screw in upper engine/gearbox connecting bolts and tighten

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to specified torque ⇒ page 79 .

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– Now step onto stepladder - VAS 5085- to lift the engine/gear‐

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box assembly using the spindles.

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– Raise engine/gearbox assembly by turning spindles approx. 8

turns.
– At the same time, lift the engine/gearbox assembly using en‐
gine and gearbox jack - V.A.G 1383 A- (2nd mechanic).
1. Installing subframe with wheel alignment
2. Installing subframe without wheel alignment
1. Wheel alignment must be carried out if holes -1- and -2- did not
line up ⇒ page 71 , Figure N37-0916
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– Install subframe using
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– Tighten the old bolts only to specified torque ⇒ Running gear,
ce
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axles, steering - front and four-wheel drive; Rep. gr. 40 ; Re‐
an
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pairing front suspension; Removing and installing subframe .
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The vehicle must not be driven in this state.
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2. If holes -1- and -2- ⇒ page 71 , Figure N37-0916, lined up before
rrectness of i
assembly subframe was loosened, wheel alignment is not nec‐
essary.
l purpos
– Install subframe with new bolts, observing the tightening se‐

quence ⇒ Running gear, axles, steering - front and four-wheel nform
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drive; Rep. gr. 40 ; Repairing front suspension; Removing and

installing subframe .
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– Bolt engine bearings onto subframe according to markings

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– Screw on nuts -1- below on left and right engine mountings ⇒

Running gear, axles, steering - front and four-wheel drive;
Rep. gr. 40 ; Repairing front suspension; Removing and in‐
stalling subframe .
– Screw in new gearbox mounting/subframe bolts -2-
⇒ page 149 .

– After subframe has been bolted to body, and engine/gearbox

assembly to subframe, remove
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– Install retaining clip for coupling rod of vehicle level sender -
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steering - front and four-wheel drive; Rep. gr. 40 ; Electric and
hole
electronic components and locations; Vehicle level sender -
spec
G78- on front axle .
es, in part or in w
t to the co
– Do not bend or kink selector lever cable. Grease cable eye
and ball socket with polycarbonate grease - G 052 142 A2-
before installing.
rrectness of i
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-direction of arrow- to position “2” and, using pliers, carefully
press ball head of selector lever cable -1- onto selector shaft
nform
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– Press selector lever cable -1- fully forwards -arrow- to engage

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– Bolt support bracket of selector lever cable to gearbox
-arrows- at marked location ⇒ Item 32 (page 41) .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install cover plate -B- -arrows- ⇒ page 201 .

– Fit heat shield -A- to vehicle underbody.

– Always renew O-rings -1-.

– Moisten new O-rings with ATF and insert.
– Ensure that O-rings are seated correctly so that they do not
slip from their seats when ATF lines are inserted.
– Insert ATF lines completely to stop in gearbox by hand.
– Do not tighten bolt -2- until ATF lines have been completely
inserted ⇒ Item 1 (page 161) .
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– Fit connector for gearbox wiring harness
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– Install noise insulation bracket -1- ⇒ General body repairs,
ce
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exterior; Rep. gr. 50 ; Body front; Assembly overview - noise
an
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insulation .
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– Push on speedometer sender connector -arrow A-.
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op Vo
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drive shafts; Removing and installing drive shafts .
agen
Prote AG.
– Install right drive shaft guard plate -arrows-. The third bolt is
not visible in the figure. ⇒ Running gear, axles, steering - front
and all-wheel drive; Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .

– Fit left and right drive shaft noise insulation to wheel housing.

noise insulation.
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all-wheel drive; Rep. gr. 44 ; Torque settings for wheell w ge .
ksbolts es n
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– Hook power steering hose into retainer -arrow-.
h re
hole
spec
– Install intake connecting piece with intake manifold flap and
es, in part or in w
exhaust gas recirculation valve ⇒ 4-cylinder diesel engine,
t to the co
mechanics (without intermediate shaft); Rep. gr. 26 ; Exhaust
gas recirculation system; Removing and installing parts of ex‐
haust gas recirculation system .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
– Plug connectors -1- and -2- into brackets under coolant tank.
his
ate
do
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– Attach intake hose to intake manifold.

p
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– Set air filter cover in place and tighten nuts -arrows- ⇒ 4-cyl‐
inder diesel engine, mechanics (without intermediate shaft);
Rep. gr. 10 ; Removing and installing engine; Tightening tor‐
ques .
– Clip on covers for nuts.
– Set engine cover in place and tighten nuts ⇒ 4-cylinder diesel

engine, mechanics (without intermediate shaft); Rep. gr. 10 ;
Removing and installing engine; Tightening torques .
– Insert dipstick -1- into guide tube.
let 36 .
⇒ page 30 .
nA n AG d G. Volkswage
– With gearbox installed, check gear wage
olks oil level in final drive
oes
not
V
⇒ page 275 . ed by gu
ara
is nte
or eo
– Finally, check ATF level
au and top up ⇒ page 151 .
th ra
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– When checking ATF level, check ATF pipe connections -A-

un
pt
an
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and -B- for leaks.

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Gearbox to engine
Item Bolt Quantity Nm
1 M12 x 67 3 65
23) M12 x 110 1 65
3 M12 x 90 1 65
42) M12 x 60 1 45
5 M10 x 45 4 45
64) M12 x 67 1 65
2) With nut
3) With retainer for wiring harness
4) With wire retainer
Item A = dowel sleeves AG. Volkswagen AG d

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5.2 Removing and installing gearbox for vehicles with 5-cylinder engines
d ara
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un
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equipment required
an
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♦ Rack - 10-222A/1-
is n
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spec
♦ Lifting tackle - 2024 A-

♦ Gearbox support - 3282- t to the co
rrectne

ss o
cial p
f inform
mer
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lkswage es n
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Passat 1997th ➤ , Passat Variant 1997 ➤
o tee
or
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5-speed sautomatic
s a
gearbox four-wheel drive 01V - Edition 04.2013 ac
ce
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nl
pt
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an
♦ Locating pins - 3393- itte
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erm
ab
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♦ Lifting aid - 3457-
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♦ Torque wrench -
es, in part or in w
V.A.G 1331-
t to the co
♦ Torque wrench -
V.A.G 1332-
rrectness of i
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V.A.G 1383 A-
nform
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ion
c
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or
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♦ Step ladder - VAS 5085-

♦ Workshop manual Passat 1997 ▸ 5-cylinder fuel injection en‐
gine, mechanics
terior
wage
5.2.1 Removing
lks es n
o ot g
byV ua
d ran
ir se te
– First
uth check whether a coded radio is fitted. If so, eobtain
o
or anti-
theft
ss
a code. ac
ce
le

un
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an
d

itte
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erm
ab
ility
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wit
is n
h re
– Remove eye of support device - 2024 A- .

ole,
spec
– Insert pin into centre hole of support device - 2024 A- and se‐
t to the co
cure with split pin.

– Fit support bracket - 10-222A- together with racks - 10-222A/
1- .
rrectne
– Hook lifting tackle - 2024 A- into spindle of support bracket -

s
10-222A- .
s o
cial p
f in

form
mer

atio
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n
c
– Raise vehicle.
i
or
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Cop py
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-arrows C-. p by
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– Remove front exhaust system with catalytic converter ⇒ 5- Prote AG.
cylinder fuel injection engine, mechanics; Rep. gr. 26 ; Re‐
moving and installing parts of exhaust system .
– Remove left drive shaft guard plate -arrows-. The third bolt is
not visible in the figure.
up.

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ise nte
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tho 5-speed automatic e ogearbox four-wheel drive 01V - Edition 04.2013
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nl
pt
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harness.
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es, in part or in w
t to the co
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– Disconnect speedometer connector -arrow A- from gearbox.
nform
ercia
– Place drip tray - V.A.G 1306- underneath.

m
at
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c
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and gearbox.
or
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– Remove ATF lines from engine/gearbox assembly -arrows-

and tie up.
– Seal ATF lines with clean plugs.
Turn crankshaft 13 turn for each bolt.


AG. Volkswagen AG d
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olksw not
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– Mark position of selector lever cable support bracket
aut
h on gear‐
ra
box housing in order to reinstall it in same position.
ss Unbolt c
ce
support bracket -arrows-.
le
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Set up gearbox support - 3282- for “automatic gearbox 01V” with
nform
ercia

m
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tion of threaded connections -1- and locating sleeves -2-.
AG. Volkswagen AG d
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– Remove nuts y-1-
Vol below at left and right on engine
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b ua
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– Removehogearbox
ris mounting/subframe securing bolts
nte-2-.
e
t or
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– Before
ss separating subframe, always use locating pins - 3393-
c
ce
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un
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-2- align.
an
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es, in part or in w
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Hole -3- may be disregarded. rrectness of i

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subframe!
nform
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a
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tion in
r
te o
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Cop py
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vehicle.
co Vo
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components.

– Lower engine/gearbox assembly by turning spindles approx 8

turns.

-arrow-.
AG. Volkswagen AG d
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nl
pt
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– Lower gearbox.
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nf
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5.2.2 Installing
– Before installing, ensure that dowel sleeves are correctly lo‐
cated.


for cleaning.

– Place gearbox jack under vehicle.
AG. Volkswagen AG d
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– Screw in one engine/gearbox connecting
Vol
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gu
each side. se
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ut
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plate together. ra
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To do this, screw in the bolts by hand and tighten to 85 Nm.
ot
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– Screw in upper engine/gearbox connecting bolts and tighten t to the co

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– Raise engine/gearbox assembly by turning spindles approx.
Vol
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– At the same time, lift the engine/gearbox assembly
au
th using en‐ eo
ra
gine and gearbox jack - V.A.G 1383 A- (2ndsmechanic).
s c
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nl
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line up ⇒ page 85 , Figure N37-0916 before subframe was loos‐
h re
hole
ened.
spec
es, in part or in w
– Install subframe using bolts originally removed. These bolts
t to the co
must be renewed following wheel alignment.
rrectness of i
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WARNING
nf
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orm
m
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or c
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essary.
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– Install subframe with new bolts, observing the tightening se‐ t. C rig
gh ht
quence ⇒ Running gear, axles, steering - front and four-wheel yri
p by
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stalling subframe .
⇒ page 149 .

AG. Volkswagen AG d
sw agen 1997 ➤ , Passat
Passat oesVariant 1997 ➤
lk not
Vo
5-speed automaticedgearbox four-wheel drive 01V - Edition
by gu
ara 04.2013
ris nte
tho eo
u
– After subframe has been bolted to body, and
ss engine/gearbox
a ra
c
assembly to subframe, remove bolt -A-.
ce
e
nl
pt
du
an
– Remove engine and gearbox jack - V.A.G 1383 A- .
itte
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erm
ab
– Apply anti-corrosion agent to point of contact between bolt
ility
ot p
-A- and oil pan.
wit
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hole
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es, in part or in w
t to the co
rrectness of i
G78- on front axle . l purpos

nf
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before installing.
orm
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or c
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lever.
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– Press selector lever cable -1- fully forwards -arrow- to engage cop Vo
by lksw
selector shaft lever -2- in position “2”.
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olkswagen AG
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– Insert ATF lines completely to stop in gearbox
olks by hand.
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ris have
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inserted ⇒ Item 8 (page 162) . autho eo
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ility
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– Plug connector into multifunction switch -2-.
wit
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– Fit connector for gearbox wiring harness and secure with lock‐
hole
spec
ing lever -3-.
es, in part or in w
t to the co
insulation .
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nf
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– Push on speedometer sender connector -arrow A-.
or c
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Install guard plates for left and right drive shafts -arrows-. The
third bolt is not visible in the figure. ⇒ Running gear, axles,
steering - front and all-wheel drive; Rep. gr. 40 ; Repairing

– Install noise insulation.

noise insulation.
– Install front wheels ⇒ Running gear, axles, steering - front and
all-wheel drive; Rep. gr. 44 ; Torque settings for wheel bolts .
– Remove support device - 10-222A- .
– Attach intake hose to intake manifold.
let 36 .
⇒ page 30 .
AG . Volkswage
– With gearbox installed, check gear oil
ksw
level
agen in final driveAG does
n
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l
⇒ page 275 . by
Vo gu
a d ran
ise
– Finally, check ATF level and
ut
ho top up ⇒ page 151 .
r tee
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pt
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and -B- for leaks.
an
itte
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ility
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es, in part or in w
t to the co
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nform
ercia
Gearbox to engine
m
at
om
ion
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in t
or
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ate
1 M12 x 75 2 65
do
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or
26) M12 x 130 1 65

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35) M12 x 130 1 65
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5 M10 x 70 1 45
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67) M12 x 130 1 65
5) With nut
7) With heat shield
Item A = dowel sleeves
5.3 Installing and removing gearbox for vehicles with V6 TDI engines


equipment required
♦ Rack - 10-222A/1-
♦ Adapter - 10-222 A/3-
♦ Lifting tackle - 2024 A-
♦ Gearbox support - 3282-
AG. Volkswagen AG d
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Cop py
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♦ Locating pins - 3393-

♦ Torque wrench -
V.A.G 1331- agen
AG. Volkswagen AG d
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♦ Torque wrench - d by V gu
ara
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♦ Engine and gearbox jack - ss c
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ion
c
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or
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♦ Workshop manual Passat 1997 ► 6-cylinder diesel engine,
mechanics
terior
5.3.1 Removing
theft code.
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connecting battery . kswagen AG does
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– Unclip covers for nuts. edb ara
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– Unscrew and remove nuts -arrows-
aut and remove engine cover. ra
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nl
pt
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ility
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– Remove heat shield above turbocharger -arrows-.

l purpos
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

– Remove securing bolts -arrows- for exhaust pipe on turbo‐

charger elbow.
– Assemble support bracket - 10-222A- in conjunction with racks

- 10-222A/1- and adapters - 10-222 A/3- .
– Loosen wheel bolts. AG. Volkswagen AG d
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– Raise vehicle. ise
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-arrows C-.
AG. Volkswagen AG d
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an
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ility
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housing -arrows-.
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
– Remove shield for left drive shaft -arrows-. The third bolt is not
om
n
visible in the figure.
c
i
or
n thi
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up.
p
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t.
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op
cylinder diesel engine, mechanics; Rep. gr. 26 ; Removing C py
t. rig
and installing parts of exhaust system .
gh ht
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co lksw
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harness.

– Pull connector off speedometer sender - G22- -arrow A-.

– Unbolt engine speed sender - G28- -arrow B- from gearbox.
– Unbolt bracket for ATF line from engine oil sump.

and gearbox.
AG. Volkswagen AG d
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d by ara
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– Separate ATF lines -1- to ATF cooler.
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an
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– Do not remove retainer -3- for ATF lines.
ility
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– Remove gearbox-side starter motor bolt -2-.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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n
c
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or
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– Mark position of selector lever cable y V support bracket on gear‐ ot gu
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box housing in order to reinstall ed bit in same position. Unbolt ara
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The symbols on the adjusting plate indicate the mounts required; nf
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– Move engine and gearbox jack - V.A.G 1383 A- with gearbox yri
p by
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by c
support - 3282- under vehicle, align adjusting plate parallel to
lksw
cted agen
gearbox and support gearbox.
Prote AG.



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– Lower engine/gearbox assembly by turning spindles approx.

8 turns.
– When doing this, lower engine/gearbox assembly via spindles,
working alternately 2 turns at a time.

-arrow-.
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ted to side in -direction of arrow-. The strut is pivoted down‐ atio

m
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– Tighten bolt of turbocharger/gearbox strut ⇒ 6-cylinder diesel
engine, mechanics; Rep. gr. 10 ; Installing and removing en‐
gine; Tightening torques . wage
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t to the co
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WARNING
AG.

essary.
quence ⇒ Running gear, axles, steering - front and four-wheel



stalling subframe .
– Connect vacuum lines to engine mountings.
⇒ page 149 .

-A- and oil pan.
olkswagen AG
en AG. V
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wag does
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and ball socket with polycarbonate greaseed
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– Fit ATF lines -1- to engine/gearbox assembly and screw tight

⇒ Item 13 (page 164) .
– Bolt bracket for ATF line to engine oil sump

⇒ Item 11 (page 164) .
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– Plug connector into multifunction switch -2-.

spec
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t to the co
ing lever -3-.

rrectne

insulation .
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– Push plug onto speedometer sender - G22- -arrow A-.

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rise Removing
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ce
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pt
inder diesel engine, mechanics; Rep. gr. 26 ; Removing and
du
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rrectness of i
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– Fit intake hose onto intake manifold.
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agen
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let 36 .
⇒ page 30 .
– With gearbox installed, check gear oil level in final drive
⇒ page 275 .
– Finally, check ATF level and top up ⇒ page 151 .

and -B- for leaks.

– Check connections -1- of ATF lines for leaks when checking

ATF level.
Bolts -2- and -3- may be disregarded in this case.
AG. Volkswagen AG d
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5.4 Removing and installing gearbox for vehicles with V6 petrol engine


equipment required
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♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
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V.A.G 1383 A-
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♦ Workshop manual Passat 1997 ▸ 6-cylinder fuel injection en‐

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5.4.1 Removing
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5. Removing and installing gearbox
– Remove bolts -arrows- and remove engine cover.

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es, in part or in w
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– Secure spindles to engine. To do this, additionally use a
shackle - 10-222A/12- on front of engine to avoid damage.
rrectness of i
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– Raise vehicle.
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-arrows C-.
moving and installing parts of exhaust system .
– Remove left and right drive shaft guard plates -arrows-. The
third bolt is not visible in the figure.
up.
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– Remove noise
s aut insulation retainer -1-. ra
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– Pull connector off speedometer sender - G22- -arrow A-.

– Unbolt engine speed sender - G28- -arrow B- from gearbox.
nf
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– Unbolt bracket for ATF line from engine oil sump.

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yV ua
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– Separate ATF lines -1- to ATF cooler.
t to the co
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– Remove gearbox-side starter motor bolt -2-.
l purpos

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5-speed automatic gearboxw gen AG
afour-wheel drive 01Vdoe-sEdition 04.2013
olks no
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– Remove bolts -1 and 4- and selector lever cable riseguard plate nte
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support bracket.
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– Move engine and gearbox jack - V.A.G 1383 A- with gearbox




-2- align. AG. Volkswagen A n G do
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nl
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– Lower gearbox.


5.4.2 Installing olkswage

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each side.

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To do this, screw in the bolts
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WARNING
2. If holes -1- and -2- ⇒ page 116 , Figure N37-0916, lined up

before assembly subframe was loosened, wheel alignment is not
necessary.



stalling subframe .
⇒ page 149 .
AG. Volkswagen AG d
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– Bolt support bracket of selector lever cable to gearbox at

marked location ⇒ Item 32 (page 41) .

– Install selector lever cable guard plate -A- and tighten bolts
-1 and 4- ⇒ page 53 .

– Fit ATF lines -1- to engine/gearbox assembly and screw tight

⇒ Item 8 (page 165) .
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– Bolt bracket for ATF line to engine oil sump

h re
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⇒ Item 12 (page 165) .

spec
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l purpos
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nform
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priv
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– Install guard plates for left and right drive shafts -arrows-. The
third bolt is not visible in the figure. ⇒ Running gear, axles,
steering - front and all-wheel drive; Rep. gr. 40 ; Repairing
– Install front exhaust system with catalytic converter ⇒ 6-cyl‐
inder injection engine, mechanics; Rep. gr. 26 ; Removing and
installing parts of exhaust system .
– Install noise insulation elements -arrows-.

noise insulation.
– Fit intake hose onto intake manifold.

– Fit engine cover and engage bolts -arrows-.

let 36 .
⇒ page 30 .
⇒ page 275 .

and -B- for leaks.
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t to the co
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Item Bolt Quantity Nm Prote
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1 M12 x 67 3 65
2 M12 x 90 1 65
3 M12 x 75 1 65
4 M10 x 60 1 45
5 M10 x 45 3 45
6 M10 x 80 1 65
7 M12 x 110 1 65
12) With nut
13) With retainer for ATF lines

5.5 Removing and installing gearbox (vehicles with 8-cylinder engine)

equipment required
♦ Rack - 10-222A/1-
♦ Hook - 10-222A/2-
♦ Spindle - 10-222 A/10-
♦ Adapter - 10-222 A/18-
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♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
V.A.G 1383 A-
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♦ Workshop manual Passat 1997 ► 8-cylinder injection engine
terior

5.5.1 Removing
theft code.
– Remove air intake duct, air filter and intake hose ⇒ 8-cylinder
fuel injection engine, mechanics; Rep. gr. 24 ; Repairing in‐
jection; Dismantling and assembling air filter .
– Drain coolant ⇒ 8-cylinder fuel injection engine, mechanics;
Rep. gr. 19 ; Removing and installing parts of cooling system;
Draining and filling coolant .
– Unclip connectors -arrows- from retainers.
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body, front 10.00 ►; Lock carrier service
position 10.00 ► .
– Unclip connector for air conditioning compressor from retainer.

– Remove oil filler neck from engine.
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hole
adapter - 10-222 A/18- faces lock carrier. spec

es, in part or in w
t to the co
– Secure third spindle - 10-222 A/10- with additional hook -
10-222A/2- to lifting eye on rear left of engine.
– Attach second additional hook - 10-222A/2- to lifting eye on
rrectness of i
rear right of engine.

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pairs, exterior; Rep. gr. 66 ; Removing and installing wheel yri
p by
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housing liners; Front wheel housing liners .
by c lksw
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– Remove front exhaust pipes ⇒ 8-cylinder fuel injection engine,
mechanics; Rep. gr. 26 ; Removing and installing parts of ex‐
haust system .
– Remove left and right drive shaft guard plates -arrows-. The
third bolt is not visible in the figure.
up.


harness.
– Pull connector off speedometer sender - G22- .
– Unbolt engine speed sender - G28- from lower mounting.

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support bracket.
– Unscrew bolt -1- of retainer for ATF lines -2- from engine.
and gearbox.
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– Remove ATF lines from engine/gearbox assembly -arrow-,
ility
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hole
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– Remove bolts -arrows- and remove stop for torque reaction
om
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support -1-.
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– Unscrew hexagon nut -1- for bracket for coolant pipe -2- from
engine sump. Remove coolant pipe as illustrated.
– Unscrew hexagon nut -3- for oil pipege-4-.
n AG.Pull oil pipe out
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doeof oil
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– Unscrew retainer -5- tfor
ho wiring harness from right engine
ris e or
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es, in part or in w
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-G78- from front left track control link -2-.

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– Remove guard plate -B- -arrows-.


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– Secure
ss gearbox to gearbox support - 3282- using bolt -A-.
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– Pull vacuum lines off engine mountings, unclip lines from sub‐
frame and tie lines to side.
-2- align.


subframe!

vehicle.
– Unscrew hexagon nut -2- for earth cable -1- from right engine
support -3-.
– Unscrew bolts -arrows- from right engine support and remove
engine support.
– Pull electrical connections off alternator and unbolt wiring har‐
ness from alternator.
– Remove starter ⇒ Electrical system;AG Rep.
. Volkgr.
swag27
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n
Removing and installing starter
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– Unbolt torque converter
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132
AG.
– Pull quick-release connection of coolant hose under left side

member off coolant pipe - not visible in the figure.
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4 turns.
– When doing this, lower engine/gearbox assembly via spindles,
rrectness of i
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-arrow-.
– Unclip lines for lambda probes from gearbox.
– Remove engine/gearbox connecting bolts.

– Carefully pull back and lower gearbox alternately.


5.5.2 Installing
– Clean ATF cooler, supplementary ATF cooler and ATF lines
before installing an exchange gearbox ⇒ page 169 .
cated.
– Threaded holes in flange shaft behind
gen AG
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– Screw in upper engine/gearbox connecting bolt -1- and tighten

– Insert side engine/gearbox connecting bolt -2- with retainer for
wiring harness -3- and screw in finger-tight.
– Push open end of wiring harness retainer -3- onto hexagon
head of connecting bolt -1-.
– Tighten connecting bolt -2- to specified torque ⇒ page 141 .
– Screw in remaining upper engine/gearbox connecting bolts
and tighten to specified torque ⇒ page 141 .
– Clip lines for lambda probes to gearbox.
– Now step onto stepladder - VAS 5085- to lift the engine/gear‐
box assembly using the spindles.

turns.
gine and gearbox jack G- .V.A.G
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– Push electrical connections onto alternator and bolt wiring
nf
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5. Removing and installing gearbox
agen
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– Fit right engine support -3- and tighten bolts -arrows- ⇒ 8-

moving and installing engine; Tightening torques .
– Attach earth cable -1- to right engine support using hexagon
nut -2-.
ened.
WARNING
2. If holes -1- and -2- ⇒ page 131 , Figure N37-0916, lined

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– Screw in new gearbox mounting/subframe bolts -2- op
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⇒ page 149 .
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lines onto engine mountings.
h re
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rrectness of i
– Bolt bracket for air conditioning lines to engine sump ⇒ Heat‐
ing and air conditioning system; Rep. gr. 87 ; Repair work on
l purpos
refrigerant circuit; Repairing parts of refrigerant circuit, vehi‐

cles 10.00 .
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– Bolt bracket -5- for wiring harness to right engine bracket.
Prote
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agen
– Insert oil pipe -4- into oil pan and tighten hexagon nut -3- ⇒ 8-
moving and installing parts of lubrication system .
– Install coolant pipe -2- and tighten hexagon nut -1- for bracket
for coolant pipe on engine sump ⇒ 8-cylinder fuel injection
engine, mechanics; Rep. gr. 19 ; Removing and installing
parts of cooling system .
– Install stop for torque reaction support -1- and tighten bolts
-arrows- to specified torque ⇒ 8-cylinder fuel injection engine,
mechanics; Rep. gr. 10 ; Removing and installing engine;
Front engine mounting .


slip from their seats when ATF
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– Reconnect speedometer sender connector - G22- .

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– Install selector lever cable guard plate -A- and tighten bolts
-1 and 4- ⇒ page 53 .

– Fit guard plate -B- -arrows- ⇒ page 201 .

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haust system .
spec
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t to the co
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liners; Front wheel housing liners .
rrectness of i
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– Install oil filler neck on engine ⇒ 8-cylinder fuel injection en‐

gine, mechanics; Rep. gr. 15 ; Removing and installing cylin‐
m
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on in
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– Clip connector for air conditioning compressor into retainer.

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exterior; Rep. gr. 50 ; Body, front 10.00 ►; Lock carrier, service op
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position 10.00 ► .
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– Clip connectors -arrows- into retainers.

– Fill with coolant ⇒ 8-cylinder fuel injection engine, mechanics;
Rep. gr. 19 ; Removing and installing parts of cooling system;
Draining and filling coolant .
– Install air intake duct, air filter and intake hose ⇒ 8-cylinder
fuel injection engine, mechanics; Rep. gr. 24 ; Repairing in‐
jection; Dismantling and assembling air filter .
let 36 .
⇒ page 30 .
⇒ page 275 .

and -B- for leaks.
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retaining plate - VW 309- ⇒ page 142 .

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– Unbolt gearbox supports on left and right.

– Fit transportation tool device - 3457- to mountings on gearbox
housing and secure.
– Hook transportation tool - 3457- with the gearbox onto work‐
shop hoist - V.A.G 1202 A- .
5.7 Securing gearbox to assembly stand


equipment required
♦ Support plate - VW 309-
♦ Support clamp - VW 313-
AG. Volkswagen AG d
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♦ Workshop hoist - V.A.G 1202 A-

rrectness of i
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– Fit transportation tool device - 3457- to mountings on gearbox

housing and secure.
– Bolt support plate - VW 309- to transportation aid - 3457- .
– Using workshop hoist - VW 309- , attach gearbox with support

plate - V.A.G 1202 A- to support clamp - VW 313- .
If the gearbox is to be turned upwards on the repair stand without
the oil being drained, the breather holes for the gearbox housing
and the final drive must be sealed and drip tray - V.A.G 1306-
placed underneath the assembly.
The aid of a second mechanic is required to turn the gearbox.
5.8 Removing and installing left and right gearbox support
AG. Volkswagen AG d
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Prote
144
AG.

equipment required
♦ Torque wrench -
V.A.G 1331-
V.A.G 1383 A-
AG. Volkswagen AG d
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5.8.1 Removing
nl
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ab
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-arrows C-.
The gearbox must be supported as illustrated in order for one or
both gearbox supports to be removed.
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is n
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spec
t to the co
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cial p
f i
nform
mer
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n
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d Passat 1997 ➤ , Passat ran Variant 1997 ➤
te
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5-speed
auth automatic gearbox four-wheel drive 01V -e oEditionra 04.2013
ss c
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5.8.2 Dismantling and assembling right and
nl
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left gearbox supports
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Vehicles with hydraulic gearbox mounting
wit
, is n
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With hydraulic gearbox mounting -H-, there is no item -C- or -B-
hole
spec
because bolt -G- is screwed directly into gearbox mounting.
es, in part or in w
t to the co
– Remove bolts -A-.
– Remove bolt -G-.
rrectness of i
– Use engine/gearbox jack - V.A.G 1383 A- and gearbox support
- 3282- to lift gearbox slightly and remove hydraulic gearbox
l purpos
mounting -H-.
– Remove gearbox support -E-.
nform
ercia
Vehicles with bonded rubber gearbox mounting

m
at
om
ion
c
in t
or
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ate
do
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– Remove bolts -A-.
– Unscrew nut -B- and remove with stop -C-.
– Remove bolt -F-.
– Use engine/gearbox jack - V.A.G 1383 A- and gearbox support
- 3282- to lift gearbox slightly and remove bonded rubber
gearbox mounting -D-.
– Remove gearbox support -E-.
5.8.3 Removing right gearbox support

Except for vehicles with V6 TDI engine:
– Remove front right exhaust system ⇒ Engine, mechanics;
Rep. gr. 26 ; Removing and installing parts of exhaust system .

– Unscrew bolts -B-.

– Remove heat shield -C-.
The right-hand heat shield is not installed on 6-cylinder TDI en‐
gines.
– Separate gearbox support -2- by removing bolts -1- from gear‐
box.
5.8.4 Removing left gearbox support agen

AG. Volkswagen AG d
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Except for vehicles with 4 and 5-cylinder engine: ed b ara
nte
ris
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– Remove front left exhaust system ⇒ Engine, mechanics; aut Rep.
h
ra
gr. 26 ; Removing and installing parts of exhaust system
ss
. c
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un
pt
– Remove bolts -1- and -4- and selector lever cable guard plate
an
d
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-A-.
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nform
ercia

m
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tion in
The left-hand heat shield is not installed on 4 and 5-cylinder en‐
r
te o
thi
gines.
s
iva
do
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rp
c
– Separate gearbox support -2- by removing bolts -1- from gear‐
um
fo
box. en
ng
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5.8.5 Installing
following:

– Clean residual locking fluid out of threaded holes in gearbox

mountings -D and H-. A thread chaser is suitable for cleaning.
– Screw in new bolts -A-.
Except for vehicles with V6 TDI engine:
– Install front right exhaust system ⇒ Engine, mechanics; Rep.
Except for vehicles with 4 and 5-cylinder engine:
– Remove front left exhaust system ⇒ Engine, mechanics; Rep.
AG. Volkswagen AG d
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Gearbox mountings left and right

rm
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Item Nm
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A 23
hole
spec
Inserted with locking fluid

es, in part or in w
Always replace
t to the co
B with F 50
G 50
rrectness of i
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mercia
a
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tion in
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Right-hand gearbox support

Item Nm
A 40
B 10
Left gearbox support

Item Nm
A 40
B 10
AG. Volkswagen AG d
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6 Checking ATF level and topping up

AG. Volkswagen AG d
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6.1 Checking ATF level ed
ris nte
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WARNING
un
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Wear eye protection.
erm
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ility
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is n
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ole,
spec
equipment required
t to the co
rrectne
♦ Torque wrench -
V.A.G 1331-
s
♦ Torque wrench -
s o
cial p
V.A.G 1332-
f inform
mer
♦ ATF filling unit -
atio
V.A.G 1924-
om
n
c
i
or
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♦ Vehicle diagnosis, testing
thi
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and information system -

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VAS 5051-
pr
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♦ Diagnosis cable, 3m with

t.
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voltage supply - C py
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VAS 5051/1- or diagnosis rig ht
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cable, 5m without voltage co Vo
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supply - VAS 5051/3-
agen
Prote AG.
6. Checking ATF level and topping up 151

Vehicles with 8-cylinder fuel injection engine have an additional

ATF cooler. An additional ATF check must be performed in these
vehicles ⇒ page 156 .
Brief description
The check of the level is based on the overflow principle depend‐
ing on the ATF temperature.
The ATF level is affected by the ATF temperature.
Checking the ATF level when the ATF temperature is too low
leads to overfilling. AG. Volkswagen AG d
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Checking the ATF level when the ATF temperature is too high d byV
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leads to under filling. orise nte
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Both an excessive and an insufficient level hinders the
ss a function c
of the gearbox.
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Test conditions
itte
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• The reservoir of the ATF filling unit - V.A.G 1924- is to be filled
ility
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only with the ATF approved for the automatic gearbox 01V.
wit
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The ATF has not been mixed with other oils.
h re
hole
spec
• Gearbox is not in emergency running mode and ATF temper‐
es, in part or in w
ature is not above approx. 30 °C.
t to the co
• Vehicle level.
rrectness of i
• Selector lever at “P”, engine running at idling speed.
l purpos
• All electrical consumers and air conditioner must be switched

off.
nform
ercia
– The drain plug with seal -1- must always be renewed.

m
at
om
– The O-ring -arrow- on ATF inspection plug -2- must always be
ion
c
renewed.
in t
or
his
ate
– The ATF fill level -3- is affected by the ATF temperature.
do
priv
cum
or
– Deflector cap -4- with opening for ATF filling unit -

f
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ng
t.
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V.A.G 1924- . If the reservoir is inserted in one of the openings,
Co
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the deflector cap must not be knocked upwards into the oil pan.
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VW ATF is available as a part. Specifications ⇒ page 8 .
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Checking ATF level
– Secure reservoir of ATF filling unit - V.A.G 1924- to vehicle.

AG. Volkswagen AG d
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ho Passat 1997 ➤e o, rPassat Variant 1997 ➤
a a
ss 5-speed automatic gearbox four-wheel drive c01V - Edition 04.2013
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-arrows C-.
r
te o
thi
– Connect vehicle diagnosis, testing and information system -
s
iva
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VAS 5051- .
rp
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– With ignition switched off, connect tester -VAS 5051- using

t.
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diagnostic cable - VAS 5051/1- or -VAS 5051/3- to diagnostic C py
t. rig
connection and advance through program until “Function/
gh ht
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component selection” is displayed ⇒ page 19 .
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– Then press “Drive (Repair group 01; 10...26; 28...39)”.
– Then press “5-speed automatic gearbox 01V”.
– Press “Functions”.
– Press “Check ATF level”.
– Press → key.
The ATF temperature should not be warmer than approx. 30 °C
at the start of the test.
– Start engine.
– Raise vehicle.
– Place drip tray -V.A.G 1306- underneath.
– Press → key.
– Bring ATF to test temperature.

Test temperature 35 °C to 45 °C

– Remove ATF inspection plug from oil pan.

If ATF drips out of inspection hole:
ATF level is OK.

Only a small amount of ATF should come out of the inspection
hole when the engine is running.
– Fit new O-ring on ATF inspection plug and tighten to 80 Nm.
This completes the ATF check.
– Switch off engine.
If no ATF drips out of inspection hole: replenish ATF
⇒ page 154 .
6.2 Topping up ATF

– Guide ATF filling unit - V.A.G 1924- in through an opening
-arrow- in deflector cap, taking care not to push deflector cap
upwards out of position.
AG. Volkswagen AG d
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ility
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– Fill with ATF using ATF filling unit - V.A.G 1924- until ATF flows
wit
, is n
out of inspection hole.

h re
hole
spec
WARNING
es, in part or in w
t to the co
An ATF level which is too low or too high will impair the function
of the gearbox.
rrectness of i
l purpos
nf
ercia
orm
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– Fit new O-ring on ATF inspection plug and tighten to 80 Nm.

– Switch off engine.
6.3 Renewing ATF

Prerequisites
• Engine is switched off.
off.
• Gearbox is not in emergency running mode and ATF temper‐
ature is not above approx. 30° C.
AG. Volkswagen AG d
• Vehicle level. lksw
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not
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• Selector lever in “P”. ised ara
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th
The drain plug with sealsmust
au be renewed. ra
c
s
ce
– Secure reservoir of ATF filling unit - V.A.G 1924- to vehicle.
le
un
pt
an
d
itte
– Raise vehicle. y li
erm
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ility
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is n
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t to the co
rrectness o
cial p
f inform
mer
atio
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c
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-arrows C-.
AG. Volkswagen AG d
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– Remove drain plug -arrow 1-. horis nte
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a
– Drain ATF. ss c
ce
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nl
pt
– Tighten new drain plug -arrow 1- ⇒ Item 1 (page 173) .
du
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itte
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– Remove ATF inspection plug -arrow 2-.
erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Guide ATF filling unit - V.A.G 1924- in through an opening
l purpos
-arrow- in deflector cap, taking care not to push deflector cap

upwards out of position.
nform
ercia
– Fill with ATF until ATF comes out of inspection hole.

m
– Screw ATF level plug in hand-tight. at

om
ion
c

in t
or
his
ate
– Start engine.
do
priv
cum
or
– Press brake pedal.

f
en
ng
t.
yi Co
op
– Shift through all selector lever positions with vehicle station‐
C py
t. rig
gh
ary, leaving selector lever in each position for about 10 sec‐
ht
pyri by
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onds.
co lksw
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cted agen
Prote AG.
6.4 Additional ATF check in vehicles with

additional ATF cooler
This check must be performed if the additional ATF cooler has
been drained or renewed.
Test conditions
off.
• ATF is topped up.
• Vehicle standing on level ground
• Selector lever at “P”, engine running at idling speed.
– Connect vehicle diagnosis, testing and information system -
VAS 5051- .
– With ignition switched off, connect tester -VAS 5051- using
diagnostic cable - VAS 5051/1- or -VAS 5051/3- to diagnostic

connection and advance through program until “Function/

component selection” is displayed ⇒ page 19 .
– Then press “Drive (Repair group 01; 10...26; 28...39)”.
– Then press “6-speed automatic gearbox 09F”.
– Press “Functions”.
– Press “Check ATF level”.
– Press → key.
The ATF temperature should not be warmer than approx. 30 °C
at the start of the test.
– Start engine.
– Raise vehicle. agen
AG. Volkswagen AG d
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V
– Place drip tray -V.A.G 1306- underneath. d by gu
ara
rise nte
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– Press → key. auth
ra
ss c
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un
pt
an
d
The upper display zone shows the ATF temperature.

itte
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erm
ab
– Start engine.
ility
ot p
wit
is n
– Raise vehicle.
h re
ole,
spec
– Run engine until an ATF temperature of at least 85 °C is at‐
tained, if necessary carry out a road test to attain this temper‐
t to the co
ature.
The thermostat in the inlet of the additional ATF cooler opens only
rrectne
at a temperature of 80 °C and only then can the cooler be filled
with ATF.
ss o
cial p
f inform
Test temperature: at least 85 °C
mer
atio
m
– Switch off engine and wait until ATF temperature has cooled
o
n
c
i
down to below 30 °C.
or
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7 Overview - all-wheel drive power train
A - Clutch A
B - Clutch B
E - Clutch E
F - Clutch F
C - Brake C
D - Brake D
G - Brake G n AG. Volkswagen AG do
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F1 - Freewheel byV
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1 - Engine utho tee
or
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2 - Torque converter with lock- ss
ce
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up clutch
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3 - Front differential
rm
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ility
4 - Automatic gearbox
ot
wit
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5 - Front final drive
hole
spec
6 - Front pinion shaft
es, in part or in w
t to the co
7 - Torsen differential
8 - Output shaft
rrectness of i
9 - Propshaft
l purpos
10 - Rear pinion shaft
nform
ercia
11 - Rear differential
m
12 - Rear final drive a

com
tion in
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Z1, Z2 and Z3 = Front intermediate drive gears.

wit
, is n
h re
Z4 and Z5 = Rear intermediate drive gears.

hole
spec
-Arrows- point in direction of travel.

es, in part or in w
t to the co
7.1 Position of selector elements with hy‐

draulic control E17
rrectness of i
The following table shows which selector elements are operated

l purpos
in the individual gears to help you deal with complaints regarding

poor acceleration and speed performance or generally with drive
train faults. The table makes it possible to determine which se‐
nf
ercia
lector elements are not operating properly.

rm
m
atio
om
Solenoid valves Clutches

n in
or c
thi
e
Solenoid valves Solenoid valves Clutch Brakes Freewheel

t
sd
iva
o
r
Position / gear N88 N89 N90 N91 N92 N93 N94 A B E F C D G 1st gear
rp
cu
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f
en
ng
R = Reverse X X X X X X
t.
yi Co
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N = Neutral X X X X X- X-
t. C rig
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D, 1st gear X X X X X X X
cop Vo
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D, 2nd gear X X
Prote
X X X X X X
AG.
D, 3rd gear X X -X X X X X X
7. Overview - all-wheel drive power train 159


D, 4th gear X -X X X X X
D, 5th gear X X -X X X X X X
2nd, 1st gear X X X X X X X
D, 5th to 4th gear X X X X X (X) X X (X)
x = Component is actuated
- = Component is not actuated
(x) = Component is actuated according to situation (driving con‐
dition)
7.2 Position of selector elements with hy‐

draulic control E18/2
The following table shows which selector elements are operated
in the individual gears to help you deal with complaints regarding
poor acceleration and speed performance or generally with drive
train faults. The table makes it possible to determine which se‐
lector elements are not operating properly.
Solenoid valves Pressure regulating valves Clutch Brakes Freewheel
Position / gear N88 N89 N90 N215 N216 N217 N218 A B E F C D G 1st gear
AG. Volkswagen AG d
R = Reverse X Xlkswagen X oes X
not X X
Vo gu
N = Neutral X X ed b X
y
X ara X -
nte X-
oris
D, 1st gear X X auth X X X e or
ac X X
ss
D, 2nd gear X X X X X X X X
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D, 3rd gear X X -X X X X X X
an
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D, 4th gear X -X X X X X
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ab
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ility
D, 5th gear X X -X X X X X X
ot
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2nd, 1st gear X X X X X X X

hole
spec
D, 5th to 4th gear X X X X X (X) X X (X)

es, in part or in w
t to the co
x = Component is actuated
rrectness of i
- = Component is not actuated

l purpos
(x) = Component is actuated according to situation (driving con‐

dition)
nform
mercia
a
com
tion in
r
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Prote AG.

8 Dismantling and assembling gearbox

Removing and installing ATF lines in vehicles with 4-cylinder en‐
gines ⇒ page 161
Removing and installing ATF lines in vehicles with 5-cylinder 110
kW engine ⇒ page 162
Removing and installing ATF lines in vehicles with 5-cylinder 125
kW engine ⇒ page 163
Removing and installing ATF lines in vehicles with V6 TDI engine
⇒ page 164 Volkswa AG. gen AG
agen do
Removing and installing ATF linesVol in vehicles with V6 petrol en‐
ksw es n
ot g
gine ⇒ page 165 d by ua
ran
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Removing and installingauATF
t lines in vehicles with 8-cylinder fuel or
ac
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ss 166
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Removing and installing additional ATF cooler ⇒ page 166
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Cleaning ATF lines and ATF cooler ⇒ page 169
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Removing and installing valve body ⇒ page 173
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8.1 Removing and installing ATF lines in vehicles with 4-cylinder engines
spec
es, in part or in w
t to the co
❑ Before tightening bolt,
rrectness of i
push in line to stop by
hand.
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2 - ATF line
nform
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m
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3 - ATF line
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❑ Always renew.
5 - O-ring
❑ Insert with ATF
❑ Always renew.
hand.
7 - O-ring
❑ Insert with ATF
❑ Always renew.
hand.
8. Dismantling and assembling gearbox 161

9 - Union nut, 30 Nm
10 - Bracket
11 - Hexagon bolt
❑ Need not be unscrewed to remove and install ATF lines.
12 - Hexagon nut, 5 Nm
13 - Clamp
14 - Bracket
❑ On engine/gearbox support
8.2 Removing and installing ATF lines in vehicles with 5-cylinder 110 kW engine
hand.
2 - O-ring
❑ Insert with ATF
❑ Always renew.
3 - ATF line
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spec
gearbox housing
t to the co
6 - O-ring
❑ Insert with ATF
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❑ Always renew.
ss
7 - O-ring
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❑ Insert with ATF

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❑ Always renew.
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11 - Bracket
12 - Hexagon socket head bolt, 25 Nm

8.3 Removing and installing ATF lines in vehicles with 5-cylinder 125 kW engine
hand.
2 - O-ring
❑ Insert with ATF n AG. Volkswagen AG do
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5 - ATF line
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❑ To cooler
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gearbox housing
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❑ Always renew.
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7 - O-ring
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9 - Hexagon socket head bolt,
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5 Nm
10 - Clamp
11 - Torque reaction support
14 - Clamp

8.4 Removing and installing ATF lines in vehicles with V6 TDI engine
hand.
2 - ATF line
❑ To cooler
❑ Note coloured markings
-arrow-
gearbox housing
3 - ATF line
❑ From cooler
-arrow-
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n
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9 - Bracket
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12 - Clamp
16 - Bracket

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8.5 Removing and installing ATF lines in vehicles with V6 petrol engine ut ra
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3 - ATF line
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❑ From cooler
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7 - Bracket
9 - ATF line
❑ To cooler
-arrow-
gearbox housing
10 - ATF line
❑ From cooler
❑ Note coloured markings -arrow-
❑ Note inscription on gearbox housing
11 - Clamp
13 - ATF line
❑ To cooler
14 - ATF line
❑ From cooler
❑ Before tightening bolt, push in line to stop by hand.

AG. Volkswagen AG d
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spec
❑ Insert with ATF
t to the co
❑ Always renew.
3 - ATF line
rrectne
❑ With connection -arrow-
from additional ATF
s
cooler to gearbox
s o
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❑ From thermostat to
inform
gearbox
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gearbox housing
o
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mostat
7 - Thermostat
hand.
hand.
10 - ATF line
❑ From gearbox to ATF cooler
❑ Threaded connections cannot be interchanged
13 - Clamp
15 - Additional ATF cooler
8.7 Removing and installing additional ATF

cooler

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8.7.1 Removing
r
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– Remove front bumper cover ⇒ General body repairs, exterior;

t.
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Rep. gr. 63 ; Front bumper 10.00 ►; Assembly overview; C py
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– Place drip tray - V.A.G 1306- underneath. cted agen
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– Thoroughly clean area around ATF line/additional ATF cooler

union.
– Disconnect ATF lines from additional ATF cooler -arrows-.
– Seal off ATF lines and additional ATF cooler with clean plugs.

– Remove bolts -1- from additional ATF cooler -arrow A-.

– Remove bolts -2- from bracket -arrow B-.
– Remove bolts -3- from additional ATF cooler -arrow A- and
remove additional ATF cooler.
8.7.2 Installing
– Insert additional ATF cooler -arrow A- and tighten bolts -3- of
additional ATF cooler ⇒ page 168 .
– Tighten bolts -2- of bracket -arrow B- ⇒ page 168 .
– Tighten bolts -1- of additional ATF cooler -arrow A-
⇒ page 168 . agen
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– Moisten O-rings -1- with ATF.
hole
spec
es, in part or in w
t to the co
– Push ATF lines -2- by hand completely into additional ATF
cooler to stop.
rrectness of i
– Do not tighten bolts -3- until ATF lines have been completely
l purpos

nform
ercia
– Check ATF line connections -2- for leaks when checking ATF
m
a
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ti
level.
on in
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– Fit front bumper cover ⇒ General body repairs, exterior; Rep.

s
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gr. 63 ; Front bumper; Assembly overview .

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1- Torx screw, 5 Nm
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2- Torx screw, 5 Nm
3- Hexagon bolt, 5 Nm

8.8 Cleaning ATF lines and ATF cooler

If there is dirt in the ATF, blow compressed air (not more than 10
bar) through ATF cooler and ATF pipes before installing gearbox.
WARNING
Wear eye protection!
– Release bracket for rigid ATF lines on gearbox ⇒ page 161 .

– Unscrew bolt -2-.
– Pull ATF lines off gearbox.
– Connect a hose to ATF line -A- and secure with a hose clip.
Hang other end of hose in a suitable container.
Blow through ATF pipe -B- with a compressed air gun.
Change hose from ATF line -A- over to ATF line -B- and repeat
procedure.
Replace O-rings -1-.
Moisten O-rings with ATF.
Insert ATF lines completely to stop in gearbox by hand.
Do not tighten bolt -2- until ATF lines have been completely in‐
serted ⇒ page 161 .
Finally, check ATF level and top up ⇒ page 151 .
When checking ATF level, check ATF pipe connections -A- and
-B- for leaks.
AG. Volkswagen AG d
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1 Removing and installing oil pan
rm
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1.1 Removing and installing oil pan
hole
spec
es, in part or in w
t to the co
1.1.1 Removing
rrectness of i
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170 Rep. gr.38 - Gears, control


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– In vehicles with noise Vol
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-arrows C-. ed
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– Place drip atray
ut - V.A.G 1306- underneath.
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– Remove drain plug -arrow 1-.
– Drain ATF.
rrectne
– Unscrew bolts on oil pan in diagonal sequence and remove oil
pan.
ss o
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mer
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The drain plug with seal must be renewed.
– Clean all four magnets in recesses of oil pan. Ensure that
magnets are seated correctly in pan.
– Install oil pan with new gasket.
– Tighten pan bolts diagonally in several stages
⇒ Item 2 (page 173) .
– Tighten new drain plug ⇒ Item 1 (page 173) .
noise insulation.
– Fill with ATF; check ATF level and top up ⇒ page 151 .
1. Removing and installing oil pan 171

2 Removing and installing ATF strainer
2.1 Removing and installing ATF strainer
2.1.1 Removing
– Remove oil pan ⇒ page 170 .
– Remove bolts for ATF strainer.
– Pull ATF strainer off valve body.
2.1.2 Installing
– Moisten seal on intake neck of strainer with ATF. AG. Volkswagen AG d
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– Carefully push intake neck into opening of valve ise
dbody
b to stop. ara
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– Tighten bolts ⇒ Item 37 (page 175) . s aut ra
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s
– Install oil pan ⇒ page 170 .
ce
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ate
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3 Removing and installing valve body

Information about which control is installed: ⇒ page 3 .
Distinguishing features: ⇒ page 24
Assembly overview of valve body for gearbox with hydraulic con‐
trol E17 ⇒ page 173 .
Assembly overview of valve body for gearbox with hydraulic con‐
trol E18/2 ⇒ page 180 .
3.1 Assembly overview - valve body for gearbox with hydraulic control E17
Dismantling and assembling procedure ⇒ page 175
WARNING
Do not run engine or tow vehicle with pan removed or when

AG. Volkswagen AG d
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⇒ page 175 .
un
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2 - Bolt, 10 Nm
erm
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❑ Tighten oil pan bolts di‐
ility
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agonally in several
wit
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stages.
ole,
spec
3 - Oil pan
t to the co
⇒ page 170
4 - Seal
rrectne
❑ Always renew.
ss
5 - Magnet
o
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❑ Qty. 4 in depressions in
form
mer
oil pan
atio
m
❑ Always clean when oil

o
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c
pan is removed
i
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❑ Ensure that magnets

sd
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are correctly seated in

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⇒ page 172
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7 - Seal
❑ Pull off ATF strainer with
separating device - Kuk‐
ko 18/0-
❑ Press onto suction col‐
lar of ATF strainer
8 - Bolt, 8 Nm
❑ Bolts securing valve body: 1 bolt M6×30; 16 bolts M6×60
3. Removing and installing valve body 173

❑ Observe tightening sequence ⇒ page 179
9 - Valve body
❑ Allocation according to gearbox code ⇒ Electronic parts catalogue (ETKA)
10 - Bracket
❑ For wiring harness
❑ Hook wiring harness into retainer.
❑ Secured with bolts for valve body
11 - Bolt, 6 Nm
12 - Gearbox speed sender - G38- or gearbox output speed sender - G195-
13 - Spacer sleeve
❑ Length: 8 mm
14 - Internal oil pipe AG. Volkswagen AG d
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❑ Always renew. olksw not
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❑ Removing and installing ⇒ page 187 orise nte
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15 - O-ring ss a c
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❑ Always renew.
nl
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❑ Moisten with ATF and insert.
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16 - Speedometer sender - G22-
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17 - O-ring
spec
es, in part or in w
❑ Always renew.
t to the co
❑ Moisten with gear oil and insert.
rrectness of i
❑ Renewing ⇒ page 197 .
l purpos
❑ Renewing selector shaft seal ⇒ page 194 .

19 - Bolt, 8 Nm
nform
ercia
20 - O-ring
m
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om
io
❑ Always renew.
n
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ate
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21 - Securing clip
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en
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❑ Always renew.
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22 - Wiring harness ht. rig
rig ht
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❑ Renewing ⇒ page 191 co Vo
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❑ Gearbox oil (ATF) temperature sender - G93- integrated in wiring harness
Prote AG.
❑ To renew wiring harness, remove and install valve body ⇒ page 175 .
❑ Unhook wiring harness from retainer ⇒ Item 10 (page 174) .
❑ Position of connector on harness: flat part of rear collar faces towards oil pan; lugs on collar are horizontal
23 - Bolt, 6 Nm
25 - Spacer sleeve
❑ Length: 20 mm

26 - Bolt, 6 Nm
27 - Bracket
❑ For solenoid valve
28 - Solenoid valve 4 - N91-
❑ With O-ring.
❑ Moisten O-ring with ATF and insert.
❑ Without O-ring
❑ Without O-ring
31 - Bolt, 6 Nm
32 - Bracket
❑ For solenoid valves
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33 - Solenoid valve 6 - N93- olks es n
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❑ With O-ring. ir se
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❑ Moisten O-ring with ATF and insert. aut or
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❑ With O-ring.
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❑ With O-ring.
hole
spec
es, in part or in w
t to the co
❑ Without O-ring
rrectness of i
❑ To replace, remove and install oil pan ⇒ page 170 and remove guide plate for parking lock mechanism
l purpos
❑ When installing, do not tighten bolts for guide plate (23 Nm) with selector lever in “P”.
37 - Bolt, 6 Nm
nform
ercia
38 - Seal
m
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❑ Always renew.
ion
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39 - ATF inspection plug his

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❑ Tightening ⇒ page 151

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3.2 Assembly sequence of valve body for

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gearbox with hydraulic control E17
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3.2.1 Removing

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– Unscrew the two bolts on ATF strainer -arrows-.
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– Lever securing clip off connector on wiring harness. t. Cop py
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– Unplug connector from gearbox speed sender - G38- .

– Remove from valve body only those bolts which are marked
with an arrow.

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Passat 1997 ➤ , Passat Variant 1997 ➤ orise nte
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5-speed automatic gearbox four-wheel drive 01V
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The bolt identified by -arrow A- is shorter than the other bolts.
pt
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– Do not loosen any other bolts. This would impair the function
erm
ab
of the valve body.
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– Detach valve body from gearbox and guide out connector from
h re
ole,
wiring harness.
spec
– Do not lay valve body on gearbox input speed sender - G182-
t to the co
on the rear.
rrectness o
cial p
f inform
mer
atio
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n
c
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3.2.2 Installing
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– Lubricate new O-rings for connector on wiring harness with p by
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ATF.
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cted agen
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– Fit connector in gearbox housing with flat part -arrow A- facing
towards oil pan.
– Align valve body with dowel pin -arrow B- to drilling in gearbox
housing -arrow C-.
– Set valve body in place, at the same time inserting pin of detent
plate -1- so that it engages in slot on selector slide -2-.
– Tighten bolts for valve body -arrows- hand-tight.

The bolt identified by -arrow A- is shorter than the other bolts.

– Tighten bolts to specified torque, working from centre out‐
wards
⇒ Item 8 (page 173) . AG. Volkswagen n AG do
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spec
t to the co
rrectne
– Plug connector onto gearbox speed sender - G38- .
ss o
cial p
f inform
mer
atio
om
n
c
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te
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– Press in securing clip for connector on wiring harness until re‐
taining tab engages.
– Lubricate seal on intake neck of ATF strainer with ATF.
– Carefully push intake neck of strainer into opening of valve
body to stop.
– Bolt on ATF strainer and tighten bolts -arrows-

⇒ Item 37 (page 175) .
⇒ Item 2 (page 173) .

3.3 Assembly overview - valve body for gearbox with hydraulic control E18/2
Dismantling and assembling procedure ⇒ page 182
WARNING
Do not run engine or tow vehicle with pan removed or when

1 - Drain plug, 40 Nm
❑ With seal
❑ Always renew.
❑ Remove to drain ATF
⇒ page 182 .
2 - Bolt, 10 Nm
❑ Tighten oil pan bolts di‐
agonally in several
stages.
3 - Oil pan
⇒ page 170
4 - Seal
❑ Always renew. n AG. Volkswagen AG do
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5 - ATF strainer d byV
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ran
❑ Removing and installing ir se tee
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⇒ page 172 au ac
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6 - Bolt, 8 Nm
nl
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❑ For securing valve body an

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16 bolts M6×60 ab
ility
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❑ Removing and installing wit

, is n
⇒ page 182
h re
hole
❑ Observe tightening se‐

spec
quence ⇒ page 186

es, in part or in w
t to the co
7 - Valve body
rrectness of i
⇒ page 182
❑ Allocation according to
l purpos
gearbox code ⇒ Elec‐

tronic parts catalogue
nform
ercia
(ETKA)
m
at
8 - Bolt, 8 Nm
om
ion
c
in t
9 - Bracket
or
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ate
❑ For wiring harness

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❑ Hook wiring harness into retainer.

for
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❑ Secured with bolts for valve body
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10 - Bolt, 6 Nm
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11 - Gearbox speed sender - G38- or gearbox output speed sender - G195- cted agen
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12 - Spacer sleeve
❑ Length: 8 mm

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c
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nl
pt
13 - Internal oil pipe
du
an
itte
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❑ Always renew.
erm
ab
ility
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14 - O-ring
h re
hole
spec
❑ Always renew.
es, in part or in w
t to the co
15 - Speedometer sender - G22- or vehicle speed sender - G68-
rrectness of i
16 - O-ring l purpos
❑ Always renew.
nform
ercia
❑ Moisten with gear oil and insert.

m
at
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ion
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or
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❑ Renewing selector shaft seal ⇒ page 194 .

at
do
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18 - Bolt, 8 Nm
um
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19 - O-ring
Co
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❑ Always renew.
ht ht
rig by
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❑ Moisten with ATF and insert. by c lksw
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20 - Securing clip
❑ Always renew.
21 - Wiring harness
❑ Gearbox oil (ATF) temperature sender - G93- integrated in wiring harness
❑ Unhook wiring harness from retainer ⇒ Item 9 (page 180) .
❑ Position of connector on harness: flat part of rear collar faces towards oil pan; lugs on collar are horizontal
22 - Bolt, 9 Nm
24 - Connector
❑ Is pulled off wiring harness in gearbox
❑ Must be pulled off before removing valve body
25 - Bolt, 6 Nm
26 - Bracket
❑ For solenoid valve
27 - Automatic gearbox pressure control valve 1 - N215-
❑ With O-ring.
❑ Without O-ring
❑ Without O-ring
30 - Bolt, 6 Nm
31 - Bracket
❑ For solenoid valves


❑ With O-ring.
❑ With O-ring.
AG. Volkswagen AG d
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34 - Automatic gearbox pressure control valve 2 - N216-Volksw not
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db ara
❑ With O-ring. rise nte
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❑ Moisten O-ring with ATF and insert. sa
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❑ Without O-ring
itte
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❑ To replace, remove and install oil pan ⇒ page 170 and remove guide plate for parking lock mechanism
pe
ility
ot
❑ When installing, do not tighten bolts for guide plate (23 Nm) with selector lever in “P”.
wit
, is n
h re
36 - Bolt, 6 Nm
hole
spec
es, in part or in w
37 - Magnet
t to the co
❑ Qty. 4 in depressions in oil pan
❑ Always clean when oil pan is removed
rrectness of i
❑ Ensure that magnets are correctly seated in oil pan
l purpos
38 - Seal
❑ Always renew.
nform
ercia
39 - ATF inspection plug

m
a
com
t
❑ Tightening ⇒ page 151
ion in
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3.4 Assembly sequence for valve body for
um
fo
en
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gearbox with hydraulic control E18/2

t.
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3.4.1 Removing
cted agen
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– Replace soiled or defective valve body.

-arrows C-. agen
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– Place drip tray - V.A.G 1306-
d b underneath.
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spec
– Remove drain plug.

t to the co
– Drain ATF.
– Unscrew bolts on oil pan in diagonal sequence and remove oil
pan.
rrectness o
cial p
f inform
mer
atio
om
n
c
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– Unscrew the two bolts on ATF strainer -arrows-.

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– Lever securing clip off connector on wiring harness. thor eo
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es, in part or in w
t to the co
rrectness of i
– Unplug connector -A- from gearbox speed sender - G38- .
l purpos
– Pull off connector -B- to gearbox speed sender - G182- .
nf
ercia
– Remove from valve body only those bolts which are marked
or
with an arrow.
m
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or c
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Bolt -arrow A- is not fitted and therefore may be disregarded.
cted agen
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– Do not loosen any other bolts. This would impair the function
of the valve body.
– Detach valve body from gearbox and guide out connector from
wiring harness.

3.4.2 Installing
– To prevent wire from being pinched when valve body is instal‐
led, route wire with connector -C- as in figure.
– Lubricate new O-rings for connector on wiring harness with
ATF.
– Fit connector in gearbox housing with flat part -arrow A- facing

towards oil pan.
– Align valve body with dowel pin -arrow B- to drilling in gearbox
housing -arrow C-.
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– Set valve body in place, at the same time inserting pin of detent
pt
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an
plate -1- so that it engages in slot on selector slide -2-.

itte
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– Tighten valve body securing bolts -arrows- hand-tight from

ility
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centre outwards.
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
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t.
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co lksw
by
cted agen
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Bolt -arrow A- is not fitted and therefore may be disregarded.

– Tighten bolts to specified torque, working from centre out‐
wards
⇒ Item 6 (page 180) .
AG. Volkswagen AG d
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es, in part or in w
t to the co
– Plug connector -A- to gearbox speed sender - G38- .
rrectness of i
– Pull wire to gearbox input speed sender upwards between
l purpos
valve body and wiring harness.

– Join connector -B- to gearbox speed sender - G182- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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– Press in securing clip for connector on wiring harness until re‐ p by
o Vo
by c
taining tab engages.
lksw
cted agen
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– Lubricate seal on intake neck of ATF strainer with ATF.
– Carefully push intake neck of strainer into opening of valve
body to stop.
– Bolt on ATF strainer and tighten bolts -arrows-

⇒ Item 36 (page 182) .
⇒ Item 2 (page 180) .

3.5 Removing and installing internal oil pipe

♦ Fitting tool - 3381-
AG. Volkswagen AG d
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Defective O-rings on the internal oil pipe allow ATF to enter dif‐
wit
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ferential, which then becomes overfilled and oil will seep out of
h re
breather holes of differential.
hole
spec
If an oil pipe is removed, it should always be renewed.
es, in part or in w
t to the co
The oil pipe must be installed only using fitting tool - 3381- . Oth‐
erwise, the oil pipe may be bent and will leak.
rrectness of i
3.5.1 Removing
l purpos
– Remove valve body with hydraulic control E17 ⇒ page 175 .
nform
ercia
– Remove valve body with hydraulic control E18/2

⇒ page 182 .
m
at
om
– Lever internal oil pipe off gearbox housing using a screwdriver. ion
c
in t
or
his
ate
do
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cum
for
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ng
t.
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t. rig
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o
by c lksw
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3.5.2 Installing
– Renew O-rings.
– Insert internal oil pipe into fitting tool - 3381- .
Open side of fitting tool - 3381- faces towards outer wall of gear‐
box.

– Drive oil pipe into gearbox housing until tool stops against
gearbox housing. Use a plastic hammer to do this.
Do not cant oil pipe. Drive in both ends of oil pipe equally.
– Install valve body with hydraulic control E17 ⇒ page 178 .
– Install valve body with hydraulic control E18/2 ⇒ page 185 .
AG. Volkswagen AG d
agen oes
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3.6 Renewing gearbox speed sender - G38- s
ce
le
un
pt
or gearbox output speed sender - G195-
an
d
itte
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rm
ab
pe
ility
ot
wit
3.6.1 Removing
, is n
h re
hole
spec
– Remove oil pan ⇒ page 170 .
es, in part or in w
t to the co
– Unplug connector from gearbox speed sender.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
– Remove gearbox speed sender -2-.

n
t.
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o
by c lksw
cted agen
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3.6.2 Installing
– Install gearbox speed sender -2- together with spacer sleeve
-1- (length: 8 mm) and tighten to specified torque
⇒ Item 10 (page 180) .

– Plug connector onto gearbox speed sender.

– Install oil pan ⇒ page 170 .
– Fill with ATF; check ATF level and topAGup
agen
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wagen151
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ility
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ole,
3.7 Renewing gearbox input speed sender -
spec
G182-
t to the co
rrectne
Distinguishing features ⇒ page 24 .
ss o
3.7.1 Gearbox with hydraulic control E17
cial p
f inform
mer
3.7.2 Removing
atio
om
n
c
i
or
n thi
te
sd
a
– Turn valve body over, and unplug connector from gearbox in‐
iv
o
pr
c
put speed sender -1-.
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unbolt gearbox input speed sender -1- from valve body.
3.7.3 Installing
The side of the sender with the plug contacts faces towards the
centre of the valve body.

– Bolt on gearbox input speed sender -1- using spacer sleeves

-2- (length: 20 mm) ⇒ Item 23 (page 174) .
– Push connector onto gearbox input speed sender -1-.

lkswage es n
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byV ua
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3.7.4 Gearbox with hydraulic control E18/2
ility
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3.7.5 Removing
h re
hole
spec
es, in part or in w
t to the co
⇒ page 182 .
– Unbolt sender for gearbox input signal -A- from gearbox.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.

AG. Volkswagen AG d
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V gu
d by Passat 1997
ara ➤ , Passat Variant 1997 ➤
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r
ut
ho 5-speed automatic gearbox four-wheel drive eo
r a 01V - Edition 04.2013
s a c
s
ce
3.7.6 Installing
e
nl
pt
du
an
itte
y li
– Bolt gearbox speed sender -A- with bolt -B- to gearbox
erm
ab
⇒ Item 22 (page 181) .
ility
ot p
wit
– To prevent wire from being pinched when valve body is instal‐ , is n
h re
led, route wire with connector -C- as in figure.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
3.8 Removing and installing wiring harness

t. rig
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pyri by
Vo
o
in gearbox
by c lksw
cted agen
Prote AG.
Removing and installing wiring harness, gearbox with hydraulic

control E18/2 ⇒ page 192 .

3.8.2 Removing
– Using a small screwdriver, lever out retaining tabs on solenoid
valve connectors and pull off connectors -A- one after the oth‐
er.
– Unhook wiring harness from retainers -B- on side of valve
body.

wage es n
– Turn valve body over, and unplug connector
yV
olks from gearbox in‐ ot g
ua
put speed sender -1-. ise
d b ran
r tee
ho
– Remove retaining clip -arrow A- sa
uand
t
unclip wiring harness or
ac
from retaining clip -arrow B-. s
ce
le
un
pt
– Pull connector -2- off solenoid valve - N91- .
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
3.8.3 Installing
rrectness of i
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following:
– When installing harness, plug connectors onto respective sol‐
nform
ercia
enoid valves.
m
a
com
t
– Clip harness into intended retaining clips. If not installed cor‐
ion in
rectly, harness can be pinched when valve body is installed.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op
C py
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3.8.5 Removing
by c lksw
cted agen
Prote AG.

⇒ page 182 .
– Using a small screwdriver, lever out retaining tabs on solenoid
valve connectors and pull off connectors -A- one after the oth‐
er.
– Unhook wiring harness from retainers -B- on side of valve
body.

– Turn valve body onto back and remove connector -1- from
pressure control valve 1 - N215- .
– Remove retaining clip -arrow A- and unclip wiring harness
from retaining clip -arrow B-.
3.8.6 Installing wage

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lks ot g
Vo
Install in reverse order of removal. ed During this step, observe the
by ua
ran
following: tho ris tee
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– When installing harness,ss plug connectors onto respective sol‐
ce
enoid valves.
e
nl
pt
du
an
itte
– Clip harness into intended retaining clips. If not installed cor‐
y li
erm
ab
rectly, harness can be pinched when valve body is installed.
ility
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, is n
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hole
spec
es, in part or in w
3.9 Renewing gearbox oil temperature
t to the co
sender (ATF) - G93-
rrectness of i
l purpos

The gearbox oil temperature sender - G93- is integrated into the nform
ercia
gearbox wiring harness.

m
at
om
3.9.2 Removing
ion
c
in t
or
his
e
– Remove wiring harness in gearbox ⇒ page 191 .

at
do
priv
3.9.3 Installing
um
for
en
ng
t.
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op
– Renew wiring harness. C py
t. rig
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– Install new wiring harness in gearbox ⇒ page 192 . cop Vo
by lksw
cted agen
Prote
AG.
The gearbox oil temperature sender - G93- is integrated into the

gearbox wiring harness.
3.9.5 Removing
– Remove wiring harness in gearbox ⇒ page 192 .
3.9.6 Installing
– Renew wiring harness.
– Install new wiring harness in gearbox ⇒ page 193 .

4 Renewing oil seal for selector shaft
4.1 Renewing oil seal for selector shaft
4.1.1 Removing

AG. Volkswagen AG d
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ility
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wit
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ole,
spec
t to the co
– Remove multifunction switch - F125- ⇒ page 197 .
rrectne
– Remove front left exhaust system ⇒ Engine, mechanics; Rep.
gr. 26 ; Removing and installing parts of exhaust system . ss o
cial p

inform
mer

atio
m
-arrow-.
o
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.

– Drive spring pin -1- out of gearbox selector lever -2- -arrow-
until gearbox selector lever can be removed from selector
shaft.
AG. Volkswagen AG d
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– Lever out seal using a screwdriver.
uthor eo
ra
s a c
s
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectne
4.1.4 Installing
ss o
– Apply ATF to circumference and space between sealing lips
cial p
f in
of seal.
form
mer
atio
om
n
c
Open side of seal faces gearbox.

i
or
n thi
te
sd
a
– Drive in new sealing ring to stop of thrust piece - 3385- , taking

iv
o
pr
care not to cant sealing ring.

um
r
fo
en
ng
t.
yi
– Push gearbox selector lever onto selector shaft and drive in
Co
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spring pin. t. C rig
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– Using a pair of pliers, carefully push selector lever cable onto
co lksw
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cted agen
selector shaft lever -2-. Prote AG.
Be careful not to bend selector shaft lever when pushing cable on

because otherwise shift mechanism cannot be precisely adjus‐
ted.
– Install multifunction switch ⇒ page 197 .
4. Renewing oil seal for selector shaft 195


– Install front left exhaust system ⇒ Engine, mechanics; Rep.
lkswage es n
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t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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fo
en
ng
t.
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Cop py
t. rig
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co lksw
by
196
cted agen
Prote AG.
Rep. gr.38 - Gears, control
5 Renewing multifunction switch -

F125-
5.1 Renewing multifunction switch - F125-

5.1.1 Removing
– Remove left wheel.
5.1.2 Vehicles with TDI engine

– Remove left drive shaft noise insulation from wheel housing
-arrows-.
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t to the co
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f inform
mer
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om

c
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or
n thi
te

sd
iva
o
r
-arrows C-.
p
cum
r
fo
en
ng

t.
yi Co
Cop py
.
– Unbolt multifunction switch - F125- from gearbox and pull
ht rig
rig ht
by
switch off selector shaft. copy Vo
by lksw
cted agen
Prote AG.
5. Renewing multifunction switch F125 197

5.1.4 Installing
Centre multifunction switch - F125- on selector shaft. Do not cant
or use force when installing. Otherwise, the switch contacts will
be damaged.
– Place multifunction switch - F125- on selector shaft. Flat sec‐
tion in splines in switch -3- must coincide with flat section on
selector shaft -1-.
– Turn switch so that dowel hole -4- in switch housing can be
fitted on dowel pin -2- on gearbox housing.
– Bolt multifunction switch - F125- to gearbox
⇒ Item 18 (page 181) .
– Installing left gearbox support ⇒ page 144 .
5.1.5 Vehicles with TDI engine n AG. Volkswagen AG do

lkswage es n
– Fit noise insulation for drive shaft at left wheel by V housing.
o ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
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le
un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install left wheel ⇒ Running gear, axles, steering - front and

nform
ercia

m

a
com
tio
noise insulation.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6 Replacing speedometer sender -

G22- or vehicle speed sender - G68-
6.1 Renewing sender

6.1.1 Removing
– Remove left wheel.

– Remove left drive shaft noise insulation from wheel housing
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
– Remove left drive shaft guard plate.
h re
hole
spec
es, in part or in w
t to the co
– Pull connector -arrow A- off sender.
– Press retaining clip of sender downwards and turn to outside rrectness of i
front -arrow-.
l purpos
– Pull out sender.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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t.
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6.1.5 Installing
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
following: Prote
cted AG.
agen
6. Replacing speedometer sender G22 or vehicle speed sender G68 199

n AG. gen AG Volkswa
Passat 1997 ➤ , Passat Variant 1997 ➤ wage does
Volks not
5-speed automatic gearbox four-wheel edrive
d by 01V - Edition 04.2013 gu
ara
ris nte
utho eo
– Replace O-rings -arrows-. ss
a ra
c
ce
e
– Insert new O-rings with gear oil.
nl
pt
du
an
itte
y li
– Insert sender.
erm
ab
ility
ot p
– Engage retaining clip on mounting bracket for flange shaft.
wit
, is n
h re
– Install left wheel ⇒ Running gear, axles, steering - front and
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

39 – Final drive - rear differential

1 Removing and installing propshaft
1.1 Assembly overview
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
ss c
ce
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un
pt
an
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
t. rig
gh
Procedure for dismantling and assembling ⇒ page 203 .
ht
pyri by
Vo
o
by c lksw
♦ No repairs may be carried out on the propshaft.
cted agen
Prote AG.
♦ The propshaft must be tied up or supported if it is disconnected

only at gearbox or rear final drive.
♦ Remove and install propshaft using assembly tool - 3298- or
assembly tool - 3405- .
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
♦ Check adjustment before replacing propshaft for complaints
concerning noise and/or vibrations ⇒ page 208 .
1. Removing and installing propshaft 201

1 - Rear final drive

2 - Propshaft
3 - Seal
❑ Renew.
❑ Pull off protective foil.
❑ Glue seal in flange
shaft.
4 - Locking plate
55 Nm
❑ Self-locking.
❑ Always renew.
❑ Threaded holes in
flange shafts for bolts
must always be
cleaned. (E.g. with
thread chaser)
AG. Volkswagen AG d
6 - Shim agen oes
olksw not
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❑ Determining thickness ised b ara
nte
⇒ page 208 ut
hor eo
a ra
s c
7 - Nut, 25 Nm s
ce
le
un
pt
8 - Stud, 10 Nm
an
d
itte
y li
rm
ab
pe
ility
⇒ page 202
ot
wit
, is n
9 - Gearbox
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing and installing stud

nform
ercia
– Remove and install stud using two lock nuts -A-.

m
a
com
tio
n in
r
te o
thi
Short thread of stud is screwed into vehicle -arrow-.

s
iva
do
r
rp
– Tighten stud ⇒ Item 8 (page 202) .

um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
202 Rep. gr.39 - Final drive - rear differential

AG. Volkswagen AG d
agen Passat 1997 ➤ oes, Passat Variant 1997 ➤
olksw not
yV gu
5-speed automatic
ed b gearbox four-wheel drive 01V ara- Edition 04.2013
nte
ris
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ut ra
1.2 Dismantling and assembling procedure s a c
s
ce
le
un
pt
an
d
itte
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erm
ab
equipment required
ility
ot p
wit
is n
♦ Spacers - 3139/3-
h re
ole,
spec
♦ Assembly tool - 3298-
t to the co
♦ Torque wrench -
V.A.G 1331-
rrectne
♦ Torque wrench -
s
V.A.G 1332-
s o
cial p
f
♦ Hexagon head bolt
inform
M 10 x 100
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Brake pedal actuator - V.A.G 1869/2-
1.2.1 Removing and installing propshaft

1.2.2 Removing
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will

be excessive, the mountings could be damaged causing rum‐

bling noises.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
♦ A twin pillar lifting platform should be used when working on
the propshaft.
– Remove rear section of exhaust system ⇒ Engine, mechan‐
ics; Rep. gr. 26 ; Removing and installing parts of exhaust
system.
– Remove guard plate -B- -arrows-.
Volkswa AG. gen AG
agen does
olksw not
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db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Check if there is a coloured mark on the propshaft and the spec

es, in part or in w
propshaft flange of the rear final drive.

t to the co
– If no marking can be found, mark position of propshaft flange

-arrow A- relative to rear final drive -arrow B- using coloured
rrectness of i
marks.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
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1.2.3 Vehicles with a threaded hole on front

o
m
f
en
ng
t.
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side of rear final drive
Co
Cop py
ht. rig
rig ht
– Screw hexagon bolt M 10 x 100 10.9 -3- into rear final drive. py by
co Vo
by lksw
cted agen
– To loosen front and rear propshaft bolts -1-, counterhold with
Prote AG.
an assembly lever -2-.
– Remove upper 3 securing bolts in each propshaft constant
velocity joint.
1.2.4 Vehicles without threaded hole in front

– Lower vehicle.

agPassat
en AG. V 1997ag➤
olksw en ,APassat
G do Variant 1997 ➤
ksw es
5-speed automaticbygearbox
Vol four-wheel drive 01V n-oEdition
t gu 04.2013
d ara
rise nte
o
– Fit brake pedal actuator - V.A.G 1869/2- .auth eo
ra
ss c
– Depress brake pedal using brake pedal actuator -
ce
e
nl
pt
V.A.G 1869/2- .
du
an
itte
y li
– Raise vehicle.
erm
ab
ility
ot p
– Remove the lower 3 securing bolts in each propshaft constant
wit
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velocity joint.
h re
hole
spec
– Lower vehicle.
es, in part or in w
t to the co
– Remove brake pedal actuator - V.A.G 1869/2- .
– Raise vehicle.
rrectness of i
– Turn both rear wheels in the same direction at the same time
l purpos
so that the propshaft rotates 12 turn (180°).

– Lower vehicle.
nform
ercia
– Fit brake pedal actuator - V.A.G 1869/2- .

m
at
om
– Depress brake pedal using brake pedal actuator.
ion
c
in t
or
– Raise vehicle.
his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
op py
1.2.6 Propshaft with tube diameter 60 mm
t. C rig
gh ht
yri by
front and rear
op Vo
by c lksw
cted agen
Prote AG.
Do not damage propshaft surface protection when removing and
installing.
– Do not set assembly tool - 3405- on balancing plates.
– Hook in assembly tool - 3405- and tighten plastic nuts.

front and 70 mm rear
installing.

– Fit assembly tool - 3298- with spacers - 3139/3- and tighten

plastic nuts.
wage
1.2.8 Propshaft with tube diameter 60 mm yV
olks es n
ot g
ua
front and 65 mm rear d b ran
ir se tee
tho
u or
Do not damage propshaft
ss
a
surface protection when removing and ac
installing.
ce
e
nl
pt
du
an
The reduced pipe diameter -arrow- may be disregarded.
itte
y li
erm
ab
ility
ot p
wit
, is n
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plastic nuts.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
at
om
ion
– Remove remaining three securing bolts on front and rear con‐

c
in t
or
stant velocity joints.

his
ate
do
riv
– Remove securing nuts -arrows- for centre bearing and remove

p
cum
or
propshaft with assembly tool.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.2.10 Installing
following:
Always renew securing bolts for propshaft.
– Clean threaded holes in the flange shafts for propshaft of
gearbox and rear final drive of all residual locking material. A
thread chaser is suitable for cleaning.
Otherwise securing bolts may shear when screwed in.

– Ensure that marks on propshaft flange -arrow A- and on gear‐

box or rear final drive -arrow B- are in line.
If a new propshaft is installed, and the factory marking on the
flange of the rear final drive is no longer visible, the radial run-out
at propshaft flange must be measured ⇒ page 223 , and the col‐
oured marking of the propshaft must be aligned with the new
marking on the propshaft flange.
– Remove seal for propshaft on flange of gearbox or rear final
drive.
– Clean flange of gearbox or rear final drive.
Sealing surface must be free of grease.
– Pull off protective foil and apply seal.

AG . Volkswage
– Screw hexagon bolt M 10 x 100
ksw
10.9
agen -3- into rear final
n AG d
odrive.
es n
Vol ot g
– To tighten front and rear by
dpropshaft bolts -1-, counterhold with
ua
ran
e
ris
an assembly lever -2- uth ⇒ Item 5 (page 202) .
o tee
or
s a ac
– Bolt propshaft centre bearing to body ⇒ Item 7 (page 202) .
s
ce
e
nl
pt
du
– Remove assembly device.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
– Tighten lower 3 securing bolts in each propshaft constant ve‐

locity joint ⇒ Item 5 (page 202) .
nform
ercia
– Bolt propshaft centre bearing to body ⇒ Item 7 (page 202) .

m
at
om
– Remove assembly device.

ion
c
in t
or
– Lower vehicle.
his
ate
do
riv

p
cum
for
en
g
– Raise vehicle.
n
t.
yi Co
Cop py
– Turn both rear wheels in the same direction at the same time ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Lower vehicle.
Prote AG.

V.A.G 1869/2- .
– Raise vehicle.
– Tighten lower 3 securing bolts in each propshaft constant ve‐
locity joint ⇒ Item 5 (page 202) .


– Tighten shield -B- to gearbox
wag-arrows-
en AG. V to 25 Nm.does
olkswagen AG
ks not
Vol gu
– Fit heat shield -A- toedvehicle
by underbody. ara
nte
is
or e
– Install rear section
au
th of exhaust system ⇒ Engine, mechanics; or a
Rep. gr. 26 ; Removing
ss and installing parts of exhaust system . c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3 Adjusting propshaft
rrectness of i
l purpos

equipment required
nform
ercia
♦ Spacers - 3139/3-
m
at
om
ion
c
in t
or
his
ate
♦ Torque wrench -
do
priv
V.A.G 1331-
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

system.


front and rear
installing.
n AG. Volkswagen AG
– Hook in assembly
olks
watool
ge - 3405- and tighten
does plastic nuts.
no
yV t gu
db ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos

installing.
nf
ercia

rm
m
atio
m

o
n in
c
plastic nuts.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

installing.

The reduced pipe diameter -arrow- may be disregarded.

plastic nuts.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
The following figures illustrate the adjustment of propshaft using
, is n
h re
assembly tool - 3298- . The adjustment of propshaft using as‐
hole
spec
sembly tool - 3405- is identical.
es, in part or in w
t to the co
– Unscrew securing nuts -arrows- for centre bearing.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
– Measure dimension -a-.

n
t.
yi Co
Cop py
– Dimensions on left and right must be the same.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.5 Table of shims

Allocate shims with ⇒ Electronic parts catalogue (ETKA) .
Measured value Shim
of dimension -a- (mm) thickness (mm)
0 … 3.0 -
3.1 … 5.0 2
5.1 … 7.0 4
7.1 … 9.0 6
9.1 … 11.0 8
11.1 … 13.0 10

1.3.6 Install calculated shims as follows:

– Unscrew plastic nuts on assembly tool -arrow A- until there is
a slight space -a- between bracket for centre bearing -2- and
stud -1- on one side.
– Insert determined shim -1- and swing bracket -2- for centre
bearing to other side.
– Fit second shim -4- on stud -3-.
– Now retighten both plastic nuts on assembly tool -arrow A-.
Centre propshaft longitudinally: AG. Volkswagen AG d
agen oes
ksw
– Slide back propshaft with assembly
byV
ol
tool to stop. not
gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Mark position of centre bearing on body -arrow A-.
ility
ot p
wit
– Then slide propshaft with assembly tool forwards to stop.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
– Mark position of centre bearing on body -B-.

om
n in
or c
– Secure centre bearing in central position -C-

thi
te
⇒ Item 7 (page 202) .

sd
iva
o
r
rp
cu
– Then remove assembly tool.

o
m
f
en
ng
t.
yi Co
– Install heat shield on vehicle underbody. Cop py
ht. rig
rig ht
– Install rear section of exhaust system ⇒ Engine, mechanics; py by
co Vo
Rep. gr. 26 ; Removing and installing parts of exhaust system .
by lksw
cted agen
Prote AG.

2 Renewing oil seals for flange shafts

(rear final drive installed)
– Observe general repair instructions
agen
AG. V⇒
olkpage 10
swagen AG. do
w es n
olks o
All the illustrations show ed
bythe left-hand side of the final drive.
V t gu
aRe‐
ran
moval and installationhoris of flange shaft and oil seal on right-hand tee
side is identical. aut or
ac
ss
ce
le
un
pt
an
d
itte
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equipment required
erm
ab
ility
ot p
♦ Drift - 2062-
wit
is n
h re
ole,
spec
♦ Torque wrench -
t to the co
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
rrectne
♦ Sealing grease -
s
G 052 128 A1-
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.1 Renewing oil seals for flange shafts
2.1.1 Removing

♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐

box mounting -V.A.G 1359/2-
♦ Support - T10149-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
Note s aut ra
c
s
ce
le
All the illustrations show the left-hand side of the final drive. Re‐
un
pt
an
d
moval and installation of flange shaft and oil seal on right-hand

itte
y li
erm
side is identical.
ab
ility
ot p
wit
is n
– Remove bolts -2- and remove heat shield.

h re
ole,
spec
– Remove bolts -1-.

t to the co
– Push parts of drive shaft together outwards and swing out of

flange shaft.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing oil seals for flange shafts (rear final drive installed) 213
If the drive shaft cannot be swung out of the flange shaft, do the
following.
– Remove wheel on respective side.
– Attach support - T10149- with a wheel bolt.
– Insert support - T10149- in engine and gearbox jack - V.A.G
1383 A- .
– Raise wheel bearing housing just enough (max. 10 cm) so that
drive shaft may be swung out of flange shaft.
WARNING
♦ Do not raise wheel bearing housing more than 10 cm.

Otherwise, the vehicle may slip off the lifting platform.
♦ If necessary, load about 50 kg ballast in the vehicle’s lug‐
gage compartment or secure the vehicle to the lifting
platform using tensioning strap - T10038- .
♦ Do not raise or lower the vehicle while the engine and
gearbox jack - V.A.G 1383 A- is positioned under the ve‐
hicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
cont'd
– Remove flange shaft securing bolt by screwing two bolts into

flange and counterholding flange shaft with a lever.
– Pull out flange shaft.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
– If dust ring is fitted, remove it using a screwdriver.

wit
is n
h re
ole,
spec
Note
t to the co
The dust ring will be destroyed during removal and must be re‐
newed.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
214
cted agen
Prote AG.
Rep. gr.39 - Final drive - rear differential
– Pry seal out using appropriate assembly lever.
2.1.2 Installing
following:
– Apply gear oil to outer circumference and sealing lips of seal.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
– Drive in new seal to stop, being carefulolknot
sw
to cant seal.
AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– If dust ring was fitted, drive in new dust ring -arrow- to stop.
– Insert flange shaft.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Screw in flange shaft bolt -arrow-, using mandrel to prevent
Co
op py
flange from turning ⇒ Item 19 (page 235) .
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Renewing oil seals for flange shafts (rear final drive installed) 215
– Install drive shafts ⇒ Rep. gr. 42 .

– Install heat shield and tighten bolts -2-. Specified torque: 25
Nm.
Attach drive shaft to flange shaft ⇒ Running gear, axles, steering
– Checking gear oil in rear final drive ⇒ page 231 .
AG. Volkswagen AG d
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AG. Volkswagen AG d
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3 Renewing oil seal for propshaft
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flange (rear final drive installed)
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un
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3.1 Renewing oil seal for propshaft flange
rm
ab
pe
ility
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hole
equipment required
spec
es, in part or in w
♦ Drive shaft fitting appliance
t to the co
- VW 391-
♦ Multipurpose tool -
rrectness of i
VW 771-
l purpos
♦ Puller hooks - VW 771/3-

♦ Drift - 3026-
nform
ercia
♦ Counterhold tool - 3028-

m
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♦ Drift sleeve - 3143-
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♦ Locking fluid - D 000 600-

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♦ 2 hexagon bolts M 8 x 30
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♦ Hexagon head bolt by c lksw
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M 10 x 100 Prote AG.
3. Renewing oil seal for propshaft flange (rear final drive installed) 217
♦ Engine and gearbox jack - V.A.G 1383 A- with universal gear‐

box mounting - V.A.G 1359/2-

3.1.1 Removing
– Only if there are no marks, mark position of rear propshaft
sections on constant velocity joints with paint
-arrows A and B-.

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side of rear final drive Volkswagen oes
not
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– Screw hexagon bolt M 10 x 100 10.9oris-3-
e into rear final drive. nte
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h
ut ra
– To loosen front and rear propshaft
ss bolts -1-, counterhold with
a c
an assembly lever -2-.
ce
le
un
pt
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d
– Remove upper 3 securing bolts in each propshaft constant

itte
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rm
velocity joint.
ab
pe
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hole
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es, in part or in w
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nform
ercia
– Lower vehicle.
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218
AG.
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Vol 1997 ➤ , PassatesVariant
not
gu
1997 ➤
by
5-speed automatic risegearbox
d four-wheel drive 01V - Editionara04.2013
ntee
ho
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ac
– Fit brake pedal actuator - V.A.G 1869/2- . ss
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pt
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d
itte
V.A.G 1869/2- .
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ab
– Raise vehicle.
ility
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– Remove the lower 3 securing bolts in each propshaft constant
h re
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velocity joint.
spec
– Lower vehicle.
t to the co
– Raise vehicle.
rrectne
s
s o
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f i
– Lower vehicle.
nform
mer
– Fit brake pedal actuator - V.A.G 1869/2- .
atio
om
n
c
– Depress brake pedal using brake pedal actuator.
i
or
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sd
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– Raise vehicle.
iv
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t.
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Cop py
t. rig
gh
– Remove remaining three securing bolts on front and rear con‐
ht
pyri by
Vo
stant velocity joints.
co lksw
by
cted agen
Prote AG.
– Separate propshaft from rear final drive, raise and tie.
– Position engine and gearbox jack - V.A.G 1383 A- with uni‐
versal gearbox support - V.A.G 1359/2- under rear final drive
and secure rear final drive.
– Remove securing bolts from rear final drive support -arrows-.
– Carefully lower rear final drive until flange is accessible.
– Mark position of pinion shaft securing nut with paint.
lkswage es n
o ot g
byV ua
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Passat 1997h➤ or , Passat Variant 1997 ➤
is tee
t or
5-speed automatic
au gearbox four-wheel drive 01V - Edition 04.2013
ac
ss
ce
e
nl
pt
3.1.5 Determining dimension “a” and dimen‐
du
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erm
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ility
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♦ Distance from flange to pinion shaft = Dimension “a”
wit
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hole
♦ Distance from flange to pinion shaft securing nut = Dimension
spec
“b”
es, in part or in w
t to the co
– Note determined measurements.
rrectness of i
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– Then bolt on counterhold - 3028- and remove securing nut for

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pinion shaft. C py
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Reuse previous hexagon nut to secure flange to pinion shaft. cop Vo
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– Screw 2 hexagon bolts M 8 x 30 -A- into flange.

– Pull off flange with drive shaft fitting appliance - VW 391- .
– Pull out seal.

AG. Volkswagen AG d
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ut
ss a 5-speed automatic gearbox four-wheel
ra
c drive 01V - Edition 04.2013
ce
e
nl
pt
du
3.1.6 Installing
an
itte
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following:
wit
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– Always renew O-ring behind flange.
hole
spec
es, in part or in w
– Apply gear oil to circumference and sealing lips of seal.
t to the co
grease - G 052 128 A1- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
thi
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– Drive in new seal to stop, being careful not to cant seal.
sd
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Prote AG.
– Drive propshaft flange onto pinion gear far enough that secur‐
ing nut can be fitted.
– The threads on the pinion gear and flange nut must be cleaned
free of grease and coated thinly with locking fluid - D 000 600- .
– Insert previous hexagon nut and tighten to position marked.
3.1.7 Checking dimension “a” and dimension

“b”.
♦ O-ring -1- must be installed during measurement.
♦ The hexagon nut must be exactly at the marked position again.
Deviation from measurement ⇒ page 220 must not be more than
± 0.3 mm.
AG. Volkswagen AG d
agen oes
– Secure hexagon nut. olksw not
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– If position of propshaft relativethto
o propshaft flange was marked
ri
eo
before removal, reinstall propshaft
s au in same position ra
c
⇒ page 201 . s
ce
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un
– If there is no marking on propshaft, determine radial run-out at pt

an
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propshaft flange ⇒ page 223 or ⇒ page 225 . y li

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t to the co
– Tighten securing bolts for rear final drive support -arrows- ⇒

rrectne
Running gear, axles, steering - front and all-wheel drive; Rep.

gr. 42 ; Repairing rear axle (vehicles with all-wheel drive); As‐
sembly overview - final drive subframe .
ss o
cial p
– Then attach propshaft to rear final drive ⇒ page 201 .

inform
mer

atio
om
n
c
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Prote AG.

4 Measuring and marking radial run-

out on propshaft flange
4.1 Measuring radial run-out on propshaft

flange
♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Radial run-out must always be measured when flange has been
removed.
Radial run-out can also be measured when final drive is installed.
If a new propshaft is to be
AGfitted
. Volksand
wagethe
n AGcoloured mark on the rear
agen does
final drive flange Volkis
swno longer visible, the position
not of the maximum
run-out (corresponds
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gu
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axis) must
tho
ris be determined and marked with a coloured nte
e o dot.
au ra
Thesscoloured mark on the propshaft will be aligned withc this col‐
ce
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oured mark.
nl
pt
du
an
itte
– Separate propshaft from rear final drive and tie up

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erm
ab
⇒ page 201 .
ility
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– Set up measuring tools.

, is n
h re
hole
– Set dial gauge to zero with 1 mm preload and position on ma‐

spec
chined surface in flange.

es, in part or in w
t to the co
so that the propshaft rotates one complete rotation.
rrectness of i
– Make a coloured mark at the point of greatest radial run-out

along outside of flange (corresponds to greatest distance from
l purpos
axis of rotation).
– Then remove previous marks on flange.
nf
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4. Measuring and marking radial run-out on propshaft flange 223

– When installing the propshaft, the marks on the propshaft

flange -arrow A- and on the rear final drive -arrow B- must be
aligned.
– Install propshaft ⇒ page 201 .
AG. Volkswagen AG d
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5 Measuring and marking radial run-

out on propshaft flange (vehicles swage
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without threaded hole in front side y Vof
olk ot g
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ran
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rear final drive) au
tho tee
or
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nl
pt
du
an
5.1 Measuring radial run-out on propshaft flange
itte
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erm
ab
ility
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wit
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equipment required
hole
spec
♦ Universal dial gauge brack‐ es, in part or in w
t to the co
et - VW 387-
♦ Assembly tool - VW 792-
rrectness of i
♦ Torque wrench -
V.A.G 1331-
l purpos
♦ Dial gauge
nf
ercia
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Prote AG.
Radial run-out must always be measured when flange has been

removed.
Radial run-out can also be measured when final drive is installed.
If a new propshaft is to be fitted and the coloured mark on the rear
final drive flange is no longer visible, the position of the maximum
run-out (corresponds to the maximum distance from the rotational
axis) must be determined and marked with a coloured dot.
The coloured mark on the propshaft will be aligned with this col‐
oured mark.
– Separate propshaft from rear final drive and tie up
⇒ page 201 .
5. Measuring and marking radial run-out on propshaft flange (vehicles without threaded hole in front side of rear final drive) 225
– Remove right shield from rear final drive.

– Fit assembly appliance - VW 792- in centre hole -arrow- for
right-hand drive shaft guard plate.
– Set up universal dial gauge bracket - VW 387- with dial gauge
on assembly appliance - VW 792- .
– Set dial gauge to zero with 1 mm preload and position on ma‐
chined surface -arrow- in flange.
so that the propshaft rotates one complete rotation.
– Make a coloured mark at the point of greatest radial run-out
along outside of flange (corresponds to greatest distance from
axis of rotation).
– Then remove previous marks on flange.
– When installing the propshaft, the marks on the propshaft

flange -arrow A- and on the rear final drive -arrow B- must be
aligned.
– Install propshaft ⇒ page 201 .
AG. Volkswagen AG d
agen oes
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pt
du
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ility
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es, in part or in w
t to the co
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at
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ion
c
in t
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ate
do
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en
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Prote AG.

6 Removing and installing rear final

drive
6.1 Removing and installing rear final drive


box mounting - V.A.G 1359/2- olksw AG. V agen AG
agen does
olksw not
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spec
t to the co

rrectne
6.1.1 Removing
ss o

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f in

form
mer
system.
atio
om
– Check if there is a coloured mark on the propshaft and the

n
c
i
or
propshaft flange of the rear final drive.

thi
te
sd
va
– If no marking can be found, mark position of propshaft flange

i
o
pr
cum
r
-arrow A- relative to rear final drive -arrow B- using coloured

fo
en
ng
marks.
t.
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Cop py
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– Separate propshaft from rear final drive and tie up yri
gh by
ht
⇒ page 201 . cop Vo
by lksw
cted agen
Prote AG.
6. Removing and installing rear final drive 227

AG. Volkswagen AG d
agen oes
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Passat 1997 ➤ , Passat Variant 1997 ➤ by Vol
gu
ara
d
5-speed automatic gearbox four-wheel orise drive 01V - Edition 04.2013 nte
eo
th
au ra
s c
– Remove left and right shields from rear
s final drive -arrows-.
ce
e
nl
pt
du
– Unbolt left and right drive shafts and tie them up.
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove nuts -arrows- and remove cover -1-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
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– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- under rear final drive.
– Secure rear final drive to universal gearbox support using a
strap.
– Remove securing bolts from rear final drive support -arrows-.

– Remove securing bolts from cross member -arrows-.

– Lower rear final drive.
6.1.2 Installing
following:
Always renew securing bolts for propshaft.
– Threaded holes in flange shaft for rear final drive propshaft
must be cleaned of residual locking fluid. A thread chaser is wage
es n
suitable for cleaning. yV
olks ot g
u b ara
ed
Otherwise securing bolts may shear when screwed in. thoris nte
e
u or
s a on rear ac
– Ensure that marks on propshaft flange -arrow A- sand
ce
final drive -arrow B- are in line.
le
un
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an
d
itte
– Remove seal for propshaft on flange of rear final drive.
y li
rm
ab
pe
ility
– Clean flange of rear final drive.
ot
wit
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Sealing surface must be free of grease.
h re
hole
spec
– Pull off protective foil and apply seal.
es, in part or in w
t to the co
rrectness of i
l purpos
– Tighten securing bolts for rear final drive support -arrows- ⇒

Running gear, axles, steering - front and all-wheel drive; Rep.
nform
ercia
gr. 42 ; Repairing rear axle (vehicles with all-wheel drive); As‐

sembly overview - final drive subframe .
m
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tion in
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by
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Prote AG.
6. Removing and installing rear final drive 229

– Tighten rear final drive to cross member -arrows- ⇒ Running

gear, axles, steering - front and all-wheel drive; Rep. gr. 42 ;
Repairing rear axle (vehicles with all-wheel drive); Assembly
overview - final drive subframe .
– Install cover -1-, if present, and bolt to cross member AG. Volkswagen AG d
-arrows- ⇒ Running gear, axles, steering - front and all-wheel lksw
agen oes
not
drive; Rep. gr. 42 ; Repairing rear axle (vehicles with all-wheel d by Vo gu
ara
drive); Assembly overview - final drive subframe . orise nte
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– Install propshaft ⇒ page 201 . s au ac
s
ce
e
nl
pt
du
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itte
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– Install drive shafts ⇒ Running gear, axles, steering - front and
erm
ab
all-wheel drive; Rep. gr. 42 ; Repairing drive shafts; Removing
ility
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and installing drive shafts .
wit
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Attach shield to rear final drive ⇒ Running gear, axles, steering -
hole
spec
front and all-wheel drive; Rep. gr. 42 ; Repairing drive shafts;
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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by c lksw
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AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Passat 1997 ➤ , Passat
e o Variant 1997 ➤
ut
ss5-speed
a automatic gearbox four-wheel drive 01V -cEdition 04.2013
ra
ce
le
un
pt
an
d
7 Checking gear oil in rear final drive
itte
y li
erm
ab
ility
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wit
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7.1 Checking gear oil in rear final drive
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– To check gear oil, remove oil plug -arrow-.
The oil level is correct when the rear final drive is filled to the lower
edge of the filler hole.
Gear oil specification ⇒ page 9
– Fill with gear oil to lower edge of filler hole.
– Screw in oil plug -arrow- ⇒ Item 10 (page 234) .
7. Checking gear oil in rear final drive 231

8 Dismantling and assembling rear fi‐

nal drive
8.1 Overview - gearbox
1 - Rear final drive housing

2 - Spacer sleeve
❑ Always renew
3 - Flange
⇒ page 246
4 - Pinion gear
❑ Is paired with crown
wheel. Always renew to‐
gether as a set.
⇒ page 246
AG. Volkswagen AG d
agen oes
5 - Cover olksw not
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d by ara
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6 - Differential horis nte
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ut ra
❑ Removing and installing ss a c
⇒ page 233
ce
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un
pt
❑ Dismantling and assem‐
an
d
itte
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bling ⇒ page 237
rm
ab
pe
ility
7 - Crown wheel
ot
wit
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❑ Is paired with pinion
h re
hole
gear (final drive gear
spec
set).
es, in part or in w
t to the co
⇒ page 237 rrectness of i
l purpos
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mercia
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tion in
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te o
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Prote AG.

9 Removing and installing differential
9.1 Removing and installing differential

equipment required
♦ Support clamp - VW 313-
♦ Engine and gearbox sup‐
port - VW 540-
♦ Torque wrench -
V.A.G 1331-
V.A.G 1383 A- with univer‐
sal gearbox mounting -
V.A.G 1359/2-
AG. Volkswagen AG d
agen oes
♦ Sealing grease - Volksw not
gu
y
G 052 128 A1- d b ara
rise nte
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ss c
ce
e
nl
pt
du
an
itte
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ab
ility
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es, in part or in w
t to the co
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Rear final drive removed

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Tighten rear final drive on assembly bracket ⇒ page 235 .
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⇒ page 259 .
co Vo
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Prote AG.
9. Removing and installing differential 233

AG. Volkswagen AG d
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1 - Breather sleeve olks
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❑ With rubber valve. rised nte
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❑ Installation position
s au ra
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⇒ page 235 s
ce
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un
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2 - Rear final drive housing 16)
an
d
itte
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ab
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pinion gear
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⇒ page 246 .
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3 - Large tapered roller bearing
spec
outer race 16)
es, in part or in w
t to the co
⇒ page 237
rrectness of i
4 - Shim S1
❑ Note thickness
l purpos
❑ Adjustment overview
⇒ page 259
nform
ercia
5 - Cover for rear final drive 16)

m
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❑ With O-ring.
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❑ Always renew O-ring.
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❑ Moisten O-ring with
r
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gear oil and insert.
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25 Nm
9 - Flange shaft
⇒ page 235
10 - Plug, 35 Nm
❑ Checking gear oil in rear final drive ⇒ page 231 .
❑ Capacity and specification ⇒ page 9
11 - Differential 16)
❑ Dismantling and assembling ⇒ page 237
13 - Bush
❑ Holds magnet in position.
❑ Drive in to stop.
14 - Magnet
❑ Clean following every removal
15 - Small tapered roller bearing outer race 16)
16 - Shim S2
❑ Note thickness
❑ Adjustment overview ⇒ page 259
17 - Seal

18 - Flange shaft
19 - Hexagon socket head bolt, 25 Nm
20 - Cover
Bolting rear final drive to assembly bracket
Removing and installing flange shaft

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9. Removing and installing differential 235

9.1.1 Removing
– Draining gear oil.
– Remove left and right-hand flange shafts.
– Mark left and right flange shafts and pull out.
– Unscrew bolts securing cover for rear final drive and remove
cover.
– Pull out differential and remove.
9.1.2 Installing
following:
– Renew O-ring for rear final drive cover and coat with oil before
installing.
– Set cover for rear final drive on final drive housing and bolt on
alternately and diagonally ⇒ Item 6 (page 234) .
– Half-fill space between sealing lip and dust lip of seals with
sealing grease - G 052 128 A1- .
– Install flange shafts and tighten ⇒ Item 8 (page 234) .
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10 Dismantling and assembling differen‐

tial
10.1 Dismantling and assembling differential

equipment required
♦ Drift - VW 295-
♦ Pressure plate - VW 401-
♦ Press tool - VW 407-
♦ Press tool - VW 408 A-
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10. Dismantling and assembling differential 237

♦ Thrust piece - VW 442-

♦ Drift sleeve - 40-21-
♦ Thrust plate - 40-105-
♦ Drift - 3138-
♦ Torque wrench -
V.A.G 1332-
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♦ Adapter - V.A.G 1582/6-
♦ Puller - Kukko 44/2-
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17) Adjustment work is required if these components are replaced
⇒ page 259 .

1 - Cover for rear final drive 17)

2 - O-ring
❑ Always renew.
❑ Insert with oil.
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⇒ page 242
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❑ Drive off with a drift ⇒ page 243 .
❑ Fit to differential cage ⇒ page 244 .
❑ Allocate according to gearbox code with ⇒ Electronic parts catalogue (ETKA) .
10 - Spring pin
❑ For securing differential pinion pin
❑ Drive in flush.
11 - Large tapered roller bearing inner race 17)
❑ Pressing on ⇒ page 243
12 - Large tapered roller bearing outer race 17)
❑ Driving out ⇒ page 243
❑ Pressing in ⇒ page 243
13 - Shim S2
❑ Note thickness
❑ Adjustment overview ⇒ page 259
14 - Threaded piece
15 - Sun wheel

16 - Planet pinion
17 - Differential pinion pin
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Driving tapered roller bearing outer race out of cover

Pressing tapered roller bearing outer race into cover
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– Insert planet pinions offset by 180° with thrust washers.
Ensure that thrust washers are not again interchanged.
– Drive in planet pinion pin.
– Press planet pinions outwards.
– Press sun wheels in -direction of arrows- and check play.
– Determine thickest shim (that can still just be fitted) for sun
wheel on each side.
– Select shims of same thickness.

Shim thickness (mm)
0.50 0.70 0.90
0.60 0.80 1.00
Allocate shim with ⇒ Electronic parts catalogue (ETKA) .

If play cannot be measured, but bevel gears can just still be

turned, the adjustment is also acceptable.
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♦ Support rail - VW 457-

♦ Removing tool - VW 460-
♦ Assembly ring - VW 470/1-
♦ Tube - VW 519-
port - VW 540-
♦ Thrust plate - 30-205-
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11. Removing and installing pinion gear and dismantling and assembling 247
♦ Pulling ring - 2003/3-

♦ Thrust plate - 3005-
♦ Counterhold tool - 3028-
♦ Thrust pad - 3062-
♦ Drift - 3138-
♦ Drift sleeve - 3143-
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♦ Drift - VW 295-
♦ Bearing preload gauge -
VAS 6222-
♦ Splitter - Kukko 17/2-
♦ Internal puller - Kukko 21/7-
♦ Counter support - Kuk‐
ko 22/2-
G 052 128 A1-
♦ Long socket insert - SW 36-
♦ 2 hexagon bolts M 8 x 30
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18) Adjustment work is required if these components are replaced

⇒ page 259 .
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1 - Nut
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⇒ page 252
❑ Fitting ⇒ page 255
❑ Measure friction torque
at the same time
⇒ page 256 .
❑ Locking ⇒ page 256
2 - Flange
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11 - Large tapered roller bearing inner race 18)

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12 - Pinion gear 18)
❑ Paired with crown wheel.
❑ If renewed, renew both.
Removing nut for pinion gear

A - Screw in 2 hexagon bolts M 8 x 30 .
B - Long socket insert - 36 mm AF-
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careful not to cant seal.
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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op
Installing flange C py
t. rig
gh ht
yri
– Drive propshaft flange onto pinion shaft far enough that se‐
p by
o Vo
by c lksw
curing nut can be fitted. Prote
cted AG.
agen
Tightening nut for pinion shaft and adjusting friction torque

A - Screw in 2 hexagon bolts M 8 x 30 .
B - Long socket insert - 36 mm AF-
– When nut is tightened, rear final drive must be supported with
engine and gearbox jack - V.A.G 1383 A- and universal gear‐
box support - V.A.G 1359/2- .
Increase torque setting slowly and check friction torque at regular
intervals. If the prescribed friction torque is exceeded, the spacer
sleeve must be renewed and the adjustment repeated. A spacer
sleeve which has been compressed too much cannot be reused.
AG. Volkswagen AG d
Measuring friction torque agen oes
olksw not
byV gu
ara
To measure friction torque, use bearing preload gauge - VAS rised
nte
6222- and long socket insert - 36 mm AF- . ut
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
11.1.1 Following friction torques are to be set
rrectness of i
New bearings Used bearings19)
l purpos
200 ... 250 Ncm 30 ... 60 Ncm
nf
ercia
19) run for at least 50 km (30 miles)
orm
m
Securing pinion shaft nut
atio
om
n in
c
– After securing nut, measure radial run-out at propshaft flange

or
thi
e
⇒ page 223 or ⇒ page 225 .

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

12 Adjusting pinion shaft and crown

wheel
12.1 General notes

Careful adjustment of the crown wheel and pinion shaft is essen‐
tial to ensure that the final drive gives long service and runs
silently. Therefore, the crown wheel and pinion shaft are matched
during production and checked on testing machines to ensure that
the mesh pattern is correct and the gears run quietly.lks The
wage position es n
for quietest running is obtained by moving dthe by pinion shaft axially
Vo ot g
ua
while maintaining the backlash within the o
ir sespecified tolerances.
ran
te
h eo
ut ra
The allowance “r” based on the master
ss
a gauge “Ro” is marked on c
outer circumference of the crown wheel. Renew gear set (crown
ce
e
nl
pt
wheel and pinion shaft) together only!
du
an
itte
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erm
12.2 Adjustment and marking of final drive gear sets
ab
ility
ot p
wit
, is n
h re
1 - Identification “O937” signi‐
hole
spec
fies Oerlikon gear set with a
es, in part or in w
ratio of 37:9.
t to the co
A Klingenberg gear set “K937”
or Gleason gear set “G937”
rrectness of i
may also be installed.
l purpos
2 - Pair number -312- of final

drive set
nf
ercia
o
3 - Allowance “r” is based on
rm
m
the test machine master gauge
atio
m
used in the production. The al‐

o
n in
c
lowance “r” is always given in

or
thi
e
1/100 mm. Example: “25” indi‐

t
sd
iva
cates r = 0.25 mm.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
12. Adjusting pinion shaft and crown wheel 257

Ro - Length of test machine

master gauge used “Ro”.
Ro - Crown wheel = 57.50 mm
R - Actual dimension between
crown wheel and face of pinion
shaft at point of quietest run‐
ning for this gear set.
Vo - Hypoid offset
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

12.3 Position of shims
S1 - Shim for crown wheel in

final drive cover
S2 - Shim for crown wheel in
final drive housing
S3 - Shim for pinion gear in fi‐
nal drive housing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
12.4 Adjustment overview Cop py
ht. rig
rig ht
py by
♦ If repairs have been carried out to the final drive, adjusting the co Vo
by lksw
pinion shaft or crown wheel and pinion is necessary only if
cted agen
Prote AG.
components have been renewed which have a direct effect on
the adjustment of the final drive. To prevent unnecessary ad‐
justments, refer to the following table:
To be adjusted: Crown wheel Pinion gear Backlash
(S1+ S2) S3 0.12 - 0.22 mm
via allowance “r”
⇒ page 264 ⇒ page 260 ⇒ page 267
Part renewed
Rear final drive housing X X X
Differential cage X X
Tapered roller bearing for X X
pinion shaft
Tapered roller bearings X X
for differential

Final drive gear set X X X

Cover for rear final drive X X
12.5 Recommended sequence for new ad‐

justment of final drive gear set
When crown wheel and pinion shaft have to be adjusted, in the . Volkswagen AG
interests of an efficient procedure, keep to the following order:swagen AG does
olk not
yV gu
♦ Determine total shim thickness “Stotal” (S1 plus S2is)edtob give ara
nte
r
specified preload on differential tapered roller bearings.
ut
ho eo
ra
sa c
♦ Determine total shim thickness “Stotal” (S3) for
s
the specified
ce
le
un
pt
preload on pinion shaft tapered roller bearings.
an
d
itte
y li
♦ Distribute total shim thickness “Stotal” (S1 plus S2) so that the
rm
ab
pe
ility
specified backlash between crown wheel and pinion shaft is
ot
wit
achieved.
, is n
h re
hole
The purpose of this adjustment is to re-establish the position of‐
spec
fering the quietest running as calculated on the test machine
es, in part or in w
t to the co
during production. The utmost care and cleanliness during all as‐
sembly work and measurements are essential to achieve a good
result.
rrectness of i
12.6 Adjusting drive pinion
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
♦ Universal measuring tool -
VW 385-
port - VW 540-
♦ Bearing preload gauge -
VAS 6222-
♦ Dial gauge
♦ Long socket insert - SW 36-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
It is necessary to readjust the pinion shaft as described below only

if the pinion shaft set, pinion shaft tapered roller bearings or final
drive housing have been renewed ⇒ page 259 .
nform
mercia
12.6.1 Determining thickness of shim "S3"

a
com
tion in
r
te o
(Adjusting pinion shaft tapered roller bearing preload).

thi
s
iva
do
– Insert both tapered roller bearing outer races without shims

r
rp
cum
fo
into housing ⇒ Page ⇒ page 254 .

en
ng
t.
yi Co
op
– Insert pinion shaft in gearbox housing with large tapered roller C py
ht. rig
bearing inner race but without spacer sleeve. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

AG. Volkswagen AG d
agen oes
olksw not
V
Passat 1997 ➤ , Passat Variant 1997 ➤ d by gu
ara
ise nte
5-speed automatic gearbox four-wheel drive 01V - Edition
thor 04.2013 eo
au ra
ss c
– Heat small tapered roller bearing inner race to approx. 100 °
ce
le
un
pt
C and fit on pinion shaft.
an
d
itte
y li
– Fit propshaft flange and tighten hexagon nut for flange
rm
ab
pe
ility
⇒ page 255
ot
wit
, is n
♦ Install new tapered roller bearings as supplied and do not lu‐
h re
hole
bricate additionally.
spec
es, in part or in w
♦ Install spacer sleeve only for final friction torque measurement
t to the co
(after determining shim “S3”).
rrectness of i
l purpos
nform
To measure friction torque, use bearing preload gauge - VAS ercia
6222- and long socket insert - 36 mm AF- .
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

200 ... 250 Ncm 30 ... 60 Ncm
– Adjust setting ring of universal measuring tool - VW 385/1- to

dimension “a” = 60 mm.
– Set sliding positioning ring to dimension “b” = 55 mm.
– Set up universal mandrel - VW 385/1- as shown. Dial gauge

extension - VW 385/15- = 9 mm long. Set universal gauge -
VW 385/30- to Ro = 57.50 mm.
– Set dial gauge (3 mm range) to zero with 2 mm preload.
– Turn pinion shaft at least 8 turns so that the tapered roller
bearings settle.

lkswage es n
o ot g
byV ua
d ran
ho
ir se Passat 1997 ➤ , Passat Variant
tee 1997 ➤
t or
5-speed automatic
au gearbox four-wheel drive 01V - Edition 04.2013
ac
ss
ce
e
nl
– Place end measuring plate on face of pinion shaft.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove master gauge and insert universal measuring tool in
nform
ercia
housing.
m
at
om
i
– Fit rear final drive cover and tighten with 4 bolts.
on
c
in t
or
– Use sliding setting ring to pull 2nd centring disc outwards until
his
ate
test gauge can still just be turned by hand.
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Determine dimension “e”. Turn mandrel until dial gauge ex‐

tension makes contact with end measuring plate and indicates
maximum deflection (return point). The measured value is di‐
mension “e” (in red scale). Example: 1.60 mm
12.6.3 Determining thickness of shim “S3”

“S3” = e - r
e - Calculated value (max. deflection)

r - Allowance (given in 1/100 mm on crown wheel)
Example:
Value indicated on dial gauge “e” 1.60 mm
Allowance “r” marked on crown wheel - 0.42 mm
Shim thickness “S3” = 1.18 mm
– The various thicknesses make it possible to achieve the exact

shim thickness required.


Shim thickness (mm)
0.95 1.20 1.45
1.00 1.25 1.50
1.05 1.30 1.55
1.10 1.35
1.15 1.40
– Remove universal test gauge.
– Remove pinion shaft and large tapered roller bearing outer
race and install shim calculated for “S3” and spacer sleeve
⇒ page 246 .
– Insert small tapered roller bearing inner race and tighten nut
for pinion shaft to prescribed friction torque ⇒ page 255 .

200 ... 250 Ncm 30 ... 60 Ncm
12.6.6 Carry out check measurement - check‐

ing dimension “r”
– Turn pinion shaft at least 8 turns so that theAGtapered
. Volkswagroller
en AG
bearings settle. olkswagen does
no
V t gu
by
Insert universal mandrel - VW 385/1-
ris
ed and measure dimension “r”.
ara
nte
tho eo
If the correct shims have been au selected, the dial gauge, read anti- ra
c
ss
clockwise on the red scale, must now indicate the given allowance
ce
e
nl
“r” within a tolerance of +0.05 mm.

pt
du
an
itte
y li
– After nut for pinion haft is secured, measure radial run-out on

erm
ab
propshaft flange and mark ⇒ page 223 or ⇒ page 225 .

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
12.7 Adjusting crown wheel

o
his
ate
do
priv
(Adjusting differential)
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
264
AG.

equipment required
♦ End dimension plate -
VW 385/17-
♦ Universal dial gauge brack‐
et - VW 387-
♦ Adjustable measuring lever olkswage es n
ot g
- VW 388- d byV ua
ran
ir se tee
♦ Adjusting device for crown utho
or
wheel - VW 521- ss
a ac
ce
e
nl
♦ Torque wrench -
pt
du
an
V.A.G 1331-
itte
y li
erm
ab
♦ Dial gauge
ility
ot p
wit
, is n
♦ Hexagon bolt M8 x 45
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
It is necessary to readjust the crown wheel when

Rear final drive housing, final drive cover, differential tapered roll‐
er bearings, differential cage or the final drive set.
is renewed.
Adjustment overview: ⇒ page 259 .
Total shim thickness “Stotal” Determining (S1 plus S2)
(Adjusting preload on differential tapered roller bearings)
• Pinion shaft removed!
If only the differential tapered roller bearings are to be replaced,
the crown wheel can be removed from differential cage. The pin‐
ion shaft need not then be removed.
– Lever out flange shaft oil seal with assembly lever.
– Remove differential tapered roller bearing outer races and re‐
move shims ⇒ page 237 .
– Press small tapered roller bearing outer race together with a
1.00 mm thick shim into housing to stop (S2 side)
⇒ page 237 .
– Install differential in housing.

The crown wheel lies on the cover side.

– Fit cover and tighten bolts to 25 Nm.
– Attach tools to differential housing on gearbox housing side.
– Turn final drive with cover side upwards.
agen
AG. Volkswagen AG d
o w es n
olks ot g
– Turn differential 8 turns in both edirections
db
yV so that tapered roller ua
ran
bearings settle. horis tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Lay measuring plate - VW 385/17- on differential.
A - dial gauge extension - 30 mm-
rrectness of i
– Fit hexagon bolt M 8 x 45 -B-.
l purpos
– Set dial gauge extension on centre of measuring plate -

VW 385/17- .
nform
ercia
– Set dial gauge (3 mm range) to zero with 2 mm preload.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Move differential up and down -direction of arrow- without

f
en
ng
t.
yi
turning.
Co
Cop py
t. rig
gh
– Read play on dial gauge.
ht
pyri by
Vo
co lksw
by
Example cted agen
Prote AG.
0.50 mm
12.7.1 “Stotal” Determining (S1+ S2)

“Stotal” = Result of measurement + preload
– If the measurement is to be repeated, turn differential 8 turns
in both directions so that the tapered roller bearings settle.
The specified bearing preload is obtained by adding a constant
preload figure (0.30 mm) to the reading obtained (0.50 mm) and
the thickness of the shim installed (1.00 mm).
Example:
Inserted shim 1.00 mm

+ Measured value 0.50 mm

+ Preload (constant) 0.30 mm
Thickness of shim 1.80 mm
– Install calculated total shim thickness (1.80 mm in example)
behind the tapered roller bearing outer race in housing (S2
side). agen
AG. Volkswagen AG d
o w es n
olks ot g
Allocate shim with ⇒ Electronic parts catalogue e(ETKA)
db
yV . ua
ran
ris tee
tho
12.7.2 Determining thickness of temporary au or
ac
ss
shim “S1”
ce
e
nl
pt
du
an
itte
y li
(crown wheel side)
erm
ab
ility
ot p
After backlash is determined, temporary shim “S1” is replaced
wit
, is n
with final shim S1.
h re
hole
spec
S1 = Stotal- S2 (inserted shim)
es, in part or in w
t to the co
Example:
S1 = 1.80 mm - 1.00 mm
rrectness of i
S1 = 0.80 mm
l purpos
Allocate shim S1 and S2 with ⇒ Electronic parts catalogue .

nf
ercia
o
rm
m
atio
m
Install calculated shims S1 on crown wheel side and S2 opposite

o
n in
or c
the crown wheel, fitting 2 shims if necessary.
thi
te
sd
iva
12.7.3 Adjusting backlash
o
r
rp
cu
o
m
f
en
ng
t.
• Pinion gear installed with S3
yi Co
Cop py
t. rig
gh
• Compensation: Stot. (S1 + S2) installed in the gearbox hous‐
ht
pyri by
Vo
o
ing.
c by lksw
cted agen
Prote AG.
– Fit final drive cover and tighten bolts to 25 Nm.

– Turn differential several times in both directions so that ta‐
pered roller bearings settle.
– Use dial gauge extension - VW 382/10- (6 mm flat).
Set adjustable measuring lever - VW 388- to dimension “a” = 60
mm.
– Turn crown wheel to stop. Set dial gauge to zero with 1 mm
preload, turn crown wheel back and read backlash. Note read‐
ing.
– Repeat measurement three times, turning crown wheel 90°
each time. Add the four results and calculate the average
backlash.
12.7.4 Calculating average backlash

Example:
1st measure‐ 0.28 mm
ment
+ 2nd measure‐ 0.32 mm
ment

+ 3rd measure‐ 0.32 mm

ment
+ 4th measure‐ 0.28 mm
ment
Total 1.20 mm
Average backlash = 1.20 mm / 4 = 0.30 mm.
If the individual measurements differ among each other by more
than 0.06 mm, either the crown wheel is improperly installed or
the crown wheel and pinion themselves are defective. Recheck
installation and if necessary renew crown wheel and pinion.
12.7.5 Determining thickness of shim S2

(opposite crown wheel side)
S2 = Inserted shim
- Average backlash agen
AG. Volkswagen AG d
oes
lksw not
+ Lift (desired averagedfor
by V backlash)
o gu
ar
e an
ris tee
Lift = 0.15 mm utho or
a ac
ss
Example:
ce
le
un
pt
an
d
Stotal (inserted shim) 1.00 mm

itte
y li
rm
ab
- Average backlash 0.30 mm
pe
ility
ot
= 0.70 mm
wit
, is n
h re
+ Lift 0.15 mm
hole
spec
S2 = 0.85 mm
es, in part or in w
t to the co

rrectness of i

l purpos
Shim thickness (mm)

nform
ercia
0.15 0.50 1.50

m
0.20 0.80
com
tion in
0.25 1.00
r
te o
thi
s
iva
do

r
rp
cum
fo
en
g
12.7.7 Determining thickness of shim S1

n
t.
yi Co
Cop py
t. rig
gh
(crown wheel side)
ht
pyri by
Vo
co lksw
by
cted
S1 = Stotal - S2
agen
Prote AG.
Example:
S1 = 1.80 mm - 0.85 mm
S1 = 0.95 mm

Shim thickness (mm)
0.15 0.50 0.90
0.20 0.60 1.00
0.30 0.70 1.20
0.40 0.80


– The final S1 shim replaces the temporary “S1” shim after the
backlash is determined.
agen
AG. Volkswagen AG d
o w es n
olks o
Install calculatededshims
by
V
S1 on crown wheel side and Sa2ra opposite
t gu
nte
the crown wheel,
thoris
fitting 2 shims if necessary. eo
au ra
Carry outsscheck measurement. c
ce
e
nl
pt
Measure backlash four times around the circumference.
du
an
itte
y li
erm
– It must be 0.12…0.22 mm.
ab
ility
ot p
If the individual measurements differ among each other by more
wit
, is n
than 0.06 mm, either the crown wheel is improperly installed or
h re
hole
the crown wheel and pinion themselves are defective. Recheck
spec
installation and if necessary renew crown wheel and pinion.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

13 Definitions:
These explanations refer only to this assembly group: Automatic
gearbox 01V, 5-speed, all-wheel drive. They are not claimed to
be generally applicable.
ATF (Automatic Transmission Fluid)
Gear oil for automatic gearbox
AG. Volkswagen AG d
agen
ATF pump Volksw
oes
not
gu
by ar
d
Supplies the automatic orisechanging of gears, all lubrication pointsante
eo
(except front final drive
au
th
and transfer gearbox) and torque con‐ ra
verter with ATF. For
ss more information, refer to ⇒ Self-study pro‐ c
ce
e
gramme No. 180 ; 5-speed automatic gearbox 01V .

nl
pt
du
an
itte
ATF level
y li
erm
ab
ility
The level of ATF in gearbox when “full”. The function and smooth‐
ot p
wit
ness of gear changes require conscientious checking and main‐
, is n
h re
tenance of the ATF level. For more information, refer to ⇒ Self-
hole
spec
study programme No. 180 ; 5-speed automatic gearbox 01V .
es, in part or in w
When measuring ATF level, refer to specifications in workshop
t to the co
manual.
Automatic gearbox 01V
rrectness of i
It is characterised by a further development of the dynamic shift
l purpos
program (DSP) and two planetary gear sets as well as a parallel

axis Torsen centre differential. For more information, refer to
⇒ Self-study programme No. 180 ; 5-speed automatic gearbox nform
ercia
01V .
m
at
Brakes
om
ion
c
in t
r
Together with the clutches, they shift between the individual for‐
o
his
e
ward gears and reverse gear of the planetary gearbox and enable
at
do
riv
the various forward gear ratios. Unlike the clutches, the brakes
p
cum
or
are supported on the gearbox housing. Further information can

f
en
ng
t.
be found in ⇒ Self-study programme No. 180 ; 5-speed automatic
yi Co
op
gearbox 01V .
C py
t. rig
gh ht
yri by
Data bus cop Vo
by lksw
cted agen
Prote AG.
Transportation of data. To do this, the electrical signals are
brought into a certain format (bus). For more information, refer to
01V and ⇒ Self-study programme No. 186 ; The CAN data bus .
Torque converter
Transmits engine torque to the automatic gearbox and acts as a
hydraulic drive-away clutch. The torque converter also includes
the lock-up clutch. For more information, refer to ⇒ Self-study
programme No. 180 ; 5-speed automatic gearbox 01V .
DSP (Dynamic shift program)
For more information, refer to ⇒ Self-study programme No. 180 ;
5-speed automatic gearbox 01V .
Self-diagnosis
The capability of the control unit
to detect faults,
to react to faults,
to store faults,
to register values and make them available in measured value
block. For more information, refer to ⇒ Self-study programme No.

180 ; 5-speed automatic gearbox 01V and the test unit instruction
manual.
“►” button
Button on VAS 5051 tester display, also referred to as “continue”
button.
Perform electrical check
A targeted check of the electronic components by performing
measurements.
Performing vehicle self-diagnosis
Connecting vehicle diagnosis, testing and information system -
VAS 5051- and then selecting, amongst other items, Read fault
memory, Perform final control diagnosis or Read measured value
block.
Vehicle diagnosis, testing and information system - VAS 5051-
The -VAS 5051- replaces and extends all functions of the previ‐
ous fault readerlk-sV.A.G
wage 1551- or vehicle esystem
s no tester -
V.A.G 1552- db
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The operating
ut
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ee
or and “Gui‐
dedssfault finding” provide the latest comprehensive technical
a ac in‐
formation
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pt
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Further information can be found in ⇒ Self-study programme No.

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202 ; Vehicle Diagnosis, Testing and Information system

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VAS 5051 .
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Freewheel/stator
h re
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spec
Ensures the torque is increased in the torque converter when

driving off.
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Freewheel/gearbox
rrectne
Technically simplifies the gear changes without interrupting the

power and ensures a constant gear change quality.
s
Gearbox speed sender - G38- or gearbox output speed sender -

s o
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G195-
f inform
mer
The sender records the gearbox output speed and transmits it to

atio
the automatic gearbox control unit. For more information, refer to

om

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01V .
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Gearbox oil temperature sender - G93-

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Monitors the temperature of the ATF to prevent the gearbox from

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overheating. It is located on the valve body within the wiring har‐
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ness to the solenoid valves. For more information, refer to ⇒ Self-
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Gearbox input speed sender - G182-
The sender records the speed of the planetary carrier of the Rav‐
igneaux planetary gear set and transmits it to the automatic
gearbox control unit. For more information, refer to ⇒ Self-study
programme No. 180 ; 5-speed automatic gearbox 01V .
Guided fault finding
An operating mode of the vehicle diagnosis, testing and informa‐
tion system - VAS 5051- .
Existing faults can be detected (and rectified) using a computer
and “guided fault finding” in a dynamic fault-finding program, “ve‐
hicle self-diagnosis” and “testing”.
13. Definitions: 271

Initialising
Activate a defined setting using a specific program sequence.
Kickdown switch - F8-
The kickdown switch is integrated in the accelerator pedal cable
or in accelerator position sender - G79- . When the accelerator
pedal is depressed to stop, the gearbox changes down for accel‐
eration. For more information, refer to ⇒ Self-study programme
No. 180 ; 5-speed automatic gearbox 01V .
Clutches
Together with the brakes, they shift between the individual for‐
ward gears and reverse gear of the planetary gearbox and enable
the various forward gear ratios. For more information, refer to
01V .
Wiring
Routing of electrical wiring and components in vehicle. AG. Volkswagen AG d
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Selector lever lock solenoid - N110- byV
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Located in the selector mechanism close to the selector lever.uth or eo
Prevents (unintentional) movement of the selector lever from
ss a po‐ ra
c
sitions “P” and “N” when the brake pedal is not depressed. For
ce
le
un
more information, refer to ⇒ Self-study programme No. 180 ; 5-
pt
an
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speed automatic gearbox 01V .
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Solenoid valves - N88- to -N90-
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Opens and closes the oil channels to the clutches and brakes
h re
ole,
according to signals from the control unit. For more information,
spec
refer to ⇒ Self-study programme No. 180 ; 5-speed automatic

gearbox 01V .
t to the co
Solenoid valve - N91- or pressure control valve 1 - N215-
rrectne
As a modulation valve, continuously regulates the quantity of ATF
delivered. For more information, refer to ⇒ Self-study programme
No. 180 ; 5-speed automatic gearbox 01V .
ss o
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Solenoid valves - N92- and -N93- or pressure control valve 2 -
inform
N216- and pressure control valve 3 - N217-
mer
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These modulation valves continuously regulate the hydraulic
om
n
pressure during gear changes to enable the clutches and brakes
c
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to open and close smoothly. For more information, refer to ⇒ Self-
te
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Solenoid valve - N94- or pressure control valve 4 - N218-

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As a modulation valve, regulates the opening and closing of the
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study programme No. 180.
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Multifunction switch - F125-
Electrical switches with various tasks. For more information, refer
to ⇒ Self-study programme No. 180 ; 5-speed automatic gearbox
01V .
Emergency running
If a sensor fails, the control unit selects substitute signals and
initiates substitute functions. If this is not possible, emergency
running is initiated.
Emergency running is a “mode of the control unit” which ensures
continued driving safety and protects the gearbox against dam‐
age when faults are detected while impairing the driving charac‐
teristics as little as possible. For more information, refer to ⇒ Self-

n AG. VolksPassat 1997
wagen AG ➤ , Passat Variant 1997 ➤
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5-speed automatic
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Oerlikon gear set utho eo
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Consists of pinion and crown wheel. As an extremely quite final
ce
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drive bevel gear with offset axis for pinion and crown wheel (hy‐
pt
an
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poid drive).
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Parallel Axis Torsen centre differential (PAT)
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Centre differential with self-acting locking function. It prevents the
h re
individual axles spinning with snow, ice and mud. For more infor‐ ole,
spec
mation, refer to ⇒ Self-study programme No. 180 ; 5-speed
automatic gearbox 01V .
t to the co
Parking lock
rrectne
The selector lever controls the parking lock wheel when the ve‐
hicle is stationary and prevents the vehicle from unintentional
rolling.
ss o
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Planetary gearbox
inform
mer
Is a mechanical component of the automatic gearbox and is
atio
switched via the clutches and brakes without interrupting power
om
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transmission.
c
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Planetary gear set
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Automatic gearbox 01V has two planetary gear sets (a Rav‐

fo
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igneaux set and a simple planetary gear set), which enables the
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selection of five forward gears and a reverse gear. For more in‐ C py
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formation, refer to ⇒ Self-study programme No. 180 ; 5-speed
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Starter inhibitor relay - J207-
The relay switches on the reversing lights when the selector lever
is in the “R” position. The signal for this comes from multifunction
switch - F125- .
The relay “enables” the starter in selector lever positions “P” and
“N”.
Valve body
Located on the bottom of the gearbox and is inside the ATF pan.
Its valves regulate and distribute hydraulic pressure via the oil
channels to the shift elements (clutches and brakes).
Control unit for automatic gearbox - J217-
The electronic control unit determines the shift points with the dy‐
namic shift program (DSP). “Self-diagnosis” monitors the function
of the gearbox. If components or sensors fail, an emergency run‐
ning program ensures that the vehicle can still be driven. For more
information, refer to ⇒ Self-study programme No. 180 ; 5-speed
Rear gear train
Two gear wheels in transfer gearbox, which are driven by the
Torsen differential and which drive the rear wheels via the prop‐
shaft and rear final drive.
Front gear train
Three gear wheels in intermediate flange for front final drive,
which are driven by the Torsen differential and which drive the
front wheels via the pinion shaft in the front differential.
AF
Abbreviation for across flats.
Tiptronic
With an additional selector gate on the right of the normal selector
gate, it is now possible to manually shift up a gear by moving the
13. Definitions: 273

selector lever to plus (+) and manually shift down a gear by mov‐
ing the selector lever to negative (-).
There are also automatic gearboxes 01V without Tiptronic and,
therefore, only one selector gate for the selector lever, as previ‐
ously.
For more information, refer to ⇒ Self-study programme No. 180 ;
5-speed automatic gearbox 01V .
Overlapping gear changes
The actuation of the appropriate shift elements agen
by
AG. Vthe control
olkswagen AGunit
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ensures smooth gear changes. For more V olksw information, refer to es not
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⇒ Self-study programme No. 180 d b ; 5-speed automatic gearbox ara
ise nte
01V . thor eo
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TCC (Torque converter lock-up
ss clutch)
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It transmits engine torque mechanically to the gearbox. For more
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itte
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information, refer to ⇒ Self-study programme No. 180 ; 5-speed
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Backlash
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Measured at the head of a tooth on the circumference of tooth
spec
head when the pinion gear is stationary. The permissible backlash
es, in part or in w
t to the co
must be adhered to.
Selector lever position display - Y6-
rrectness of i
Shows the position of the selector lever and the gear selected with
Tiptronic in a display in the dash panel insert. For more informa‐
l purpos
tion, refer to ⇒ Self-study programme No. 180 ; 5-speed auto‐

matic gearbox 01V .
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Selector lever lock
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Prevents (unintentional) movement of the selector lever from po‐

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c
sitions “P” and “N” when the brake pedal is not depressed. For
or
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more information, refer to ⇒ Self-study programme No. 180 ; 5-

t
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speed automatic gearbox 01V .

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Ignition key withdrawal lock yi

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39 – Final drive - front differential

1 Checking oil in front final drive
1.1 Checking oil in front final drive

♦ Hexagon key extension, 8 mm - 3247-

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Oil level must be checked with gearbox installed.
– Drive vehicle a short distance to warm up gear oil.
rrectness of i
– Position vehicle over pit or on 4-pillar hoist so that it stands
level.
l purpos
– Switch off engine and allow gear oil to settle for about 5 mi‐
nutes.
nform
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at
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c
– Remove right drive shaft noise insulation from wheel housing

in t
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-arrows-.
at
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1. Checking oil in front final drive 275

AG. Volkswagen AG d
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1.1.2 Continuation for all vehicles d by
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– Remove oil plug.
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The oil level is correct when the front final drive is filled to the lower
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edge of the filler hole.
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– Allow excess gear oil to pour out or top up as necessary.
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Specification ⇒ page 8
hole
spec
– If gear oil needs to be replenished following repair work, fill
es, in part or in w
t to the co
front final drive slowly and evenly over a period of at least 5
minutes until gear oil drips out over lower edge of oil filler hole.
A filling time of at least 5 minutes is necessary so that oil can
rrectness of i
spread evenly throughout gearbox.
l purpos
– Screw in old plug.
nf
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– Drive vehicle a short distance to warm up gear oil.
orm
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atio
– Check oil level in front final drive again.
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– When oil level is correct, renew oil plug for front final drive
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⇒ Item 4 (page 277) .
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– Fit noise insulation for drive shaft at right wheel housing.
276 Rep. gr.39 - Final drive - front differential

2 Repairing front final drive

(Gearbox installed)
1 - Seal
❑ Between final drive and
gearbox housing
2 - Shim
❑ Behind tapered roller
bearing outer race
3 - Tapered roller bearing outer
race
4 - Plug, 30 Nm
❑ With seal
❑ Always renew.
5 - Bolt, 23 Nm
6 - Right flange shaft
7 - Oil seal for right flange shaft
8 - Bolt, 23 Nm
❑ Observe tightening se‐
quence ⇒ page 294
9 - Final drive cover
10 - Shim
❑ Behind tapered roller AG. Volkswagen AG d
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11 - Tapered roller bearing out‐ rised ara
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12 - O-ring s
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❑ Always renew.
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13 - Differential
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14 - Torsen differential (PAT)

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❑ Renew complete if damaged

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15 - Seal
rrectne
16 - Bolt, 35 Nm
❑ For checking gear oil in transfer box ⇒ page 298 .
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❑ Always renew.
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17 - Bolt, 23 Nm
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18 - Transfer box
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❑ Repairing ⇒ page 301

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❑ For draining gear oil in transfer box ⇒ page 299 . Cop py
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2. Repairing front final drive 277

20 - Bolt, 23 Nm
21 - Dowel pin
❑ Qty. 2
22 - Intermediate flange for front final drive
23 - Dowel sleeve
24 - Seal
25 - Roll pin
26 - Lever
❑ For selector shaft
27 - Seal
❑ For selector shaft
28 - Bolt, 23 Nm
29 - Oil seal for left flange shaft
30 - Input gear
❑ For speedometer sender - G22- .
❑ Installation position ⇒ page 287
31 - Left flange shaft
32 - Bearing bracket for flange shaft
33 - Deep groove ball bearing for flange shaft
34 - Retaining ring agen
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❑ Square cross usection
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❑ To replace, sremove and install left flange shaft ⇒ page 282
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2.1 Renewing seal for right flange shaft

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278
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Rep. gr.39 - Final drive - front differential Prote AG.

equipment required
♦
♦ Oil seal extractor lever -
VW 681-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench - agen
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♦ Sealing grease - horis nte
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♦ Workshop manual Passat 1997 ►, Running gear - front and
Prote AG.
four-wheel drive
2.1.1 Removing
– Only loosen drive shaft/wheel hub bolt and wheel bolts when
vehicle is standing on its wheels.
– Remove wheel.


-arrows-.
2.1.3 All vehicles except for V6 TDI

– Remove right drive shaft guard plate -arrows-. The third bolt
is not visible in the figure.
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– Remove right drive shaft -1- ⇒ Running gear, axles, steering
hole
spec
es, in part or in w
t to the co
– Remove flange shaft bolt using mandrel to prevent flange from
turning.
rrectness of i
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– Pull out right flange shaft.

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– Remove flange shaft oil seal.
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2.1.5 Installing
grease - G 052 128 A1- .
Open side of seal faces gearbox.
– Drive in new seal to stop, being careful not to cant seal.
– Install right flange shaft.
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– Install flange shaft bolt -arrow- using mandrel to prevent flange
hole
spec
from turning ⇒ Item 5 (page 277) .
es, in part or in w
t to the co
rrectness of i
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– Install right drive shaft -1- ⇒ Running gear, axles, steering -

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– Install right drive shaft guard plate -arrows-. Third bolt cannot
be seen in figure ⇒ Running gear, axles, steering - front and


2.1.8 Continuation for all vehicles . Volkswagen AG

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– Install wheel ⇒ Running gear, axles, steering - front and all- by
Vol
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wheel drive; Rep. gr. 44 ; Specified torques for wheel bolts .rised ara
nte
tho eo
– With gearbox installed, check gear oil level in front final sdrive
au ra
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⇒ page 275 . s
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2.2 Renewing oil seal for left flange shaft
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♦
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♦ Tube - 32-109- agen

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♦ Tube - 2040-
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♦ Drift - 3384-
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♦ Torque wrench -
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♦ Torque wrench -
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V.A.G 1332- urposes, in part or in wh
t to the co
♦ Oil extraction unit -
V.A.G 1358 A-
rrectne
G 052 128 A1-
ss o
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four-wheel drive
2.2.1 Removing left flange shaft

– Only when vehicle is standing on its wheels may the left drive
shaft/wheel hub bolt and left and right wheel bolts be loosened.


housing -arrows-.

– Remove left drive shaft guard plate -arrows-. The third bolt is
not visible in the figure.
2.2.4 Continuation for all vehicles AG. Volkswagen AG d

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– Remove left drive shaft -1- ⇒ Runningbygear, Vol axles, steering - not
gu
front and all-wheel drive; Rep. gr. r40ised; Repairing drive shafts; ara
nte
Removing and installing drive shafts
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– Unscrew gear oil inspection plug -arrow- and draw off at least
an
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0.5 litre gear oil from front final drive using oil extraction device
erm
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- V.A.G 1358 A- .
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It is essential that the gear oil is extracted from the front final drive;
h re
ole,
otherwise the gear oil will mix with the ATF.

spec
– Remove speedometer sender ⇒ page 199 .

t to the co
– Detach bracket for connector from flange shaft mounting

bracket.
rrectness o
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mer
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– Unbolt flange shaft mounting bracket -arrows-.

2.2.5 Removing oil seal

– Remove circlip -arrow A- for deep groove ball bearing.
– Press flange shaft out of flange shaft mounting bracket.

– Pull out flange shaft oil seal using oil seal extractor - VW 681- .
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2.2.6 Removing deep groove ball bearing

– Press deep groove ball bearing out of mounting bracket.
2.2.7 Installing deep groove ball bearing

– Press new deep groove ball bearing into mounting bracket.
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grease - G 052 128 A1- .
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Rep. gr.39 - Final drive - front differential
– Drive in new seal to stop of thrust piece, taking care not to cant
seal.
Lugs on drive gear must engage in slots on flange shaft.
– Place speedometer drive gear on flange shaft.
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2.2.9 Installing left flange shaft

– Replace O-ring -arrow B- in flange shaft mounting bracket.
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– Check that there are no sharp edges on gearbox end of flange s
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shaft; deburr edges if necessary.

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– Bolt on flange shaft mounting bracket -arrows-

⇒ Item 28 (page 278) .
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– Attach connector bracket to flange shaft mounting bracket.

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– Install speedometer sender ⇒ page 199 .

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– Install left drive shaft -1- ⇒ Running gear, axles, steering - front
and all-wheel drive; Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– With gearbox installed, check gear oil level in front final drive
⇒ page 275 .

– Install left drive shaft guard plate -arrows-. Third bolt cannot
be seen in figure ⇒ Running gear, axles, steering - front and


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2.3 Replacing front final drive/gearbox
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housing sealing ring
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equipment required
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V.A.G 1358 A-


♦ Workshop manual Passat 1997e►,
n ARunning
G. Volkswaggear
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four-wheel drive olks
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♦ Workshop manual rPassat
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1997 ► Engine, mechanics nte
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A defective oil seal
ss will allow ATF or axle oil to escape
a into the ra
c
torque converter bell housing via the central breather in the oil
ce
le
un
seal (between the two sealing lips).
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In addition, a defective seal can allow ATF to enter the differential.
erm
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This will become overfilled and ATF will escape from the front final
ility
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2.3.1 Removing
spec
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– Raise vehicle.
– Remove wheel.
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s
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-arrows-.
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– Remove front right exhaust pipe ⇒ Engine, mechanics; Rep.
– Remove right drive shaft guard plate -arrows-. The third bolt


– Unscrew gear oil inspection plug -arrow- and draw off at least
0.5 litre gear oil from front final drive using oil extraction device
- V.A.G 1358 A- .

turning.
– Remove right-hand gearbox support ⇒ page 144 .
– Unscrew bolts securing cover for front final drive and remove
cover.
– Pull out differential and remove.
– Remove tapered roller bearing outer race -1- for differential

and shim -2- behind outer race from gearbox housing by hand.
Thickness of shim -2- is calibrated; the shim must not be replaced
with another shim of different thickness.
– Removing left flange shaft ⇒ page 283 .
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– Pull out seal.

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The sealing ring extractor lever must be applied behind both seal‐
erm
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ence of sealing ring, because this would damage sealing surface

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2.3.5 Installing
nf
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– Examine sealing ring seat in gearbox for damage; reface sur‐

atio
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face if necessary.
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2. Repairing front final drive
– Push sealing ring onto thrust piece - 3383- with protruding

sealing lip of sealing ring facing towards tool.
– Drive in new seal to stop.
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– Insert shim -2- and tapered roller bearing outer race -1- for
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– Insert differential in gearbox housing.

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– Renew O-ring.
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– Install cover for front final drive.

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torques in se‐ ot g
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quence indicated ⇒ Item 8 (page r277)
ised . ran
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– Install right gearbox support s⇒
s a page 144 .
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– Install left flange shaft ⇒ page 283 .
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– Install flange shaft bolt using drift to prevent flange from turning
ole,
spec
⇒ Item 5 (page 277) .
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⇒ page 275 .
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not visible in the figure. ⇒ Running gear, axles, steering front
and all-wheel drive; Repair group 40; Servicing drive shafts;
– Install front right exhaust system ⇒ Engine, mechanics; Rep.


2.3.8 Continuation for all vehicles ksw

agen
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– Install wheel ⇒ Running gear, axles, steering ise
d b- front and all- ara
nte
wheel drive; Rep. gr. 44 ; Specified torques
thor for wheel bolts . eo
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2.4 Renewing O-ring on cover for front final
s
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2.4.1 Removing
– Raise vehicle.
– Remove wheel.


-arrows-.
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2.4.3 All vehicles except for V6 TDI ss c
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– Remove right drive shaft guard plate -arrows-. The third bolt d
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V.A.G 1358 A- .
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– Remove right-hand gearbox support ⇒ page 144 .
– Unscrew bolts securing cover for front final drive and remove
cover.
2.4.5 Installing
following:

– Renew O-ring.
– Install cover for front final drive.

Tightening sequence:
♦ Stage 1: tighten bolts -1-,-2- and -3- hand-tight.
♦ Stage 2: tighten bolts -1- to-12- to specified torques in se‐
quence indicated ⇒ Item 8 (page 277) .
– Install right gearbox support ⇒ page 144 .
– Install flange shaft bolt using drift to prevent flange from turning
⇒ Item 5 (page 277) .
⇒ page 275 .
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not visible in the figure. ⇒ Running gear, axles, steering front

sd
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and all-wheel drive; Repair group 40; Servicing drive shafts;

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– Install front right exhaust system ⇒ Engine, mechanics; Rep. C py
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2.4.8 Continuation for all vehicles ss
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– Install wheel ⇒ Running gear, axles, steering - front and all-
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wheel drive; Rep. gr. 44 ; Specified torques for wheel bolts .
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3 Axle oil in transfer box
3.1 Checking axle oil in transfer box and re‐

plenishing
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spec

t to the co
level.
All vehicles except for V6 TDI
rrectne

ss o

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– To check final drive oil, remove oil plug -arrow B-.

mer
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Oil level is correct when transfer box is filled to lower edge of filler
o
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hole.
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– Allow excess gear oil to pour out or top up as necessary.

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Specifications ⇒ page 8 .
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– Always renew bolts.
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– Tighten new oil plug -arrow B- ⇒ Item 16 (page 277) .
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3.2 Draining axle oil in transfer box or filling

after repairs
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♦ Workshop manual Passat 1997 ► Engine, mechanics Cop py
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3.2.1 Additional required information
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level.
All vehicles except for V6 TDI
3.2.2 Draining gear oil.

– Remove drain plug -arrow A- and drain gear oil.
– Always renew drain plug.
– Screw in new drain plug -arrow A- ⇒ Item 19 (page 277) .
3. Axle oil in transfer box 299

3.2.3 Filling gear oil

– Remove inspection plug -arrow B- for gear oil and top up to
lower edge of hole with gear oil.
Specifications ⇒ page 8 .
– Screw in old plug.
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reattached or installed for the road test; then remove and reinstall ed by gu
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– Carry out a road test of at least 15 minutes pure drivingsstime, c
check gear oil in transfer gearbox and top up if necessary
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⇒ page 298 .
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Only after a road test is it ensured that the newly added gear oil
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Oil level is correct when transfer box is filled to lower edge of filler
hole
hole.
spec
es, in part or in w
– Always renew plug.
t to the co
– When oil level is correct, renew oil plug -arrow B- for transfer
box ⇒ Item 16 (page 277) .
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4 Repairing transfer box

The components shown in the following illustration can be re‐
moved with the gearbox in the vehicle.

23 Nm
2 - Rear flange shaft
3 - Seal
❑ For rear flange shaft
4 - Bolt, 23 Nm
❑ For housing cover
❑ Qty. 4
5 - Housing cover
❑ With vibration damper
6 - O-ring
❑ Coat with final drive
gear oil
7 - Retaining ring
❑ For deep groove ball
bearing olkswagen AG
⇒ Item 8 (page AG. Von
301)
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8 - Deep
ss
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❑ For gear wheel 1
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❑ Pressing off
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⇒ page 303
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❑ Pressing on
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⇒ page 303
ole,
spec
9 - Gear wheel 1
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❑ For rear final drive gear

set
rrectne
❑ If damaged, always renew together with gear wheel 2 ⇒ Item 17 (page 302) .
❑ To remove and install, pull out of transfer box housing ⇒ Item 13 (page 302) towards the rear, together
s
with circlip ⇒ Item 7 (page 301) and deep groove ball bearing ⇒ Item 8 (page 301) .
s o
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10 - Retaining ring
inform
mer
❑ For needle bearing ⇒ Item 11 (page 301)

atio
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11 - Needle bearing
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❑ For gear wheel 1 ⇒ Item 9 (page 301)

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❑ Remove only to renew

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❑ To renew bearing, heat transfer box housing ⇒ Item 13 (page 302) to approx. 100 °C and drive out
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needle bearing towards rear using a drift
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❑ Driving in to stop using sleeve - 30-21-
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12 - Bolt, 23 Nm
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agen
❑ Loosen or tighten diagonally and in steps
4. Repairing transfer box 301

13 - Transfer gearbox housing

14 - Tensioning nut
❑ For rear flange shaft ⇒ Item 2 (page 301)
15 - Needle bearing
❑ For gear wheel 2 ⇒ Item 17 (page 302) AG. Volkswagen AG d
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❑ Renewing ⇒ page 315 rised
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16 - Retaining ring ss a ra
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❑ Secures needle bearing ⇒ Item 15 (page 302) in transfer box housing ⇒ Item 13 (page 302)
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17 - Gear wheel 2
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❑ For rear final drive gear set
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❑ If damaged, always renew together with gear wheel 1 ⇒ Item 9 (page 301) .
, is n
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❑ To remove and install, remove transfer box housing ⇒ Item 13 (page 302) ⇒ page 304 and pull out
hole
spec
together with ⇒ Item 18 (page 302) , ⇒ Item 19 (page 302) and ⇒ Item 23 (page 302) .
es, in part or in w
t to the co
18 - Deep groove ball bearing
❑ For gear wheel 2 ⇒ Item 17 (page 302)
rrectness of i
❑ Pressing off ⇒ page 303
l purpos
19 - Retaining ring
nform
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❑ Secures deep groove ball bearing ⇒ Item 18 (page 302) in transfer box housing ⇒ Item 13 (page 302) .
m
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20 - Washer
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ion
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❑ For deep groove ball bearing ⇒ Item 18 (page 302) .
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❑ Clip on guide plate ⇒ Item 21 (page 302) before installing

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21 - Guide plate
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22 - Bolt, 10 Nm ht. Cop py
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24 - Seal
25 - Torsen differential (PAT)
❑ Renew complete if damaged
26 - Seal
27 - Magnet
28 - Dowel pin
❑ Qty. 2
29 - Bleeder connection
❑ For transfer box
❑ With cover pushed on
❑ Installation position: Breather must project 10 to 11 mm from housing without cover
30 - Bolt, 23 Nm
31 - Intermediate flange for front final drive
32 - Seal

33 - Dowel sleeve
34 - Input pinion
❑ For front final drive
35 - Intermediate pinion
❑ Installation position: Gear marking points to transfer box
36 - Drive pinion
❑ Installation position: Gear marking points to transfer box
37 - Seal
Pressing off deep groove ball bearing for gear wheel 1
AG. Volkswagen AG d
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Pressing on deep groove ball bearing for gear wheel 1
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Pressing off deep groove ball bearing for gear wheel 2

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AG. Volkswdrive
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Pressing on deep groove ball ed bearing for
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4.1 Removing and installing transfer box
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4.1.1 Removing
– Remove front exhaust system with catalytic converter ⇒ En‐
gine, mechanics; Rep. gr. 26 ; Removing and installing parts
of exhaust system .

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Passat 1997 ➤ o, rPassat
Variant 1997 ➤
ac
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s 5-speed automatic gearbox four-wheel drive 01V - Edition 04.2013
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– Support gearbox from below using engine/gearbox jack -
es, in part or in w
V.A.G 1383 A- with universal gearbox support -
t to the co
V.A.G 1359/2- .
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– Use engine/gearbox jack to lift gearbox slightly and remove
gearbox mounting -D- and -H-.
The left and right-hand gearbox supports -E- remain on gearbox.
– Place -Auffangwanne V.A.G 1306- underneath.
– Drain gear oil from transfer box ⇒ page 299 .
– Loosen bolts -A- and -C- for transfer box housing -2- in diag‐
onal sequence and remove.
– Do not loosen bolts -B-.
Carefully pull transfer gear housing off gearbox towards rear.
Take care that Torsen differential does not drop out of housing.
AG. Volkswagen AG d
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– Pull Torsen differential to rear off output shaft.

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4.1.5 Installing
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following:
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Rep. gr.39 - Final drive - front differential Prote
cted AG.
agen
– Make sure that dowel pins -arrow A- and -arrow B- are fitted.
– Fit new gasket -D-.
– Fit cleaned magnets in cast retainer -1- in intermediate flange.
– Fit Torsen differential onto output shaft splines and drive pin‐
ion of front gear train, rotating it slightly.
– Check that fitted Torsen differential can be turned by hand.
– Fit transfer gearbox housing complete with installed gears and

rear flange shaft onto gearbox flange.
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gen AG d
– Insert bolts -A- and V-C-olksfor transfer box housing -2-
wa oes
noand
t gu tighten
in steps to prescribed
ed by torque in diagonal sequence ara
⇒ Item 12 (page
thoris 301) . nte
eo
au ra
– Install leftss and right gearbox mountings ⇒ page 144 . c
ce
e
nl
pt

du
an
itte
y li
erm
– Install front exhaust system with catalytic converter ⇒ Engine,

ab
ility

ot p
wit
haust system .
, is n
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hole
– Fill transfer gearbox with gear oil and check ⇒ page 298 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.2 Renewing seal for rear flange shaft

nf
ercia
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m
atio

om
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(Gearbox installed)
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4. Repairing transfer box
agen
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♦ Sealing grease - G 052 128 A1-

4.2.1 Removing
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– Remove front exhaustVosystem
lksw with catalytic converter
oes
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gr. 26 ; Removing and installing arparts
an
of exhaust system
thori . tee
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– Remove heat
ss shield -A- from vehicle underbody. c
ce
le
un
pt

an
d
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rm

ab
pe
ility
ot

wit
, is n
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– Drain gear oil from transfer box ⇒ page 299 .

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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te o
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te
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5-speed
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ss
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– Unbolt rear flange shaft, securing flange shaft against turning
nl
pt
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with a drift.
itte
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ab
ility
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es, in part or in w
t to the co
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– Remove oil seal using a suitable screwdriver.

t.
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4.2.2 Installing
following:
grease - G 052 128 A1- .
– Drive seal in to stop with press piece - 3402- .
– Secure rear flange shaft with hexagon socket head bolt
⇒ Item 1 (page 301) .
– Install front exhaust system with catalytic converter ⇒ Engine,
haust system .

4.3 Renewing seal on intermediate flange

for front final drive
AG. Volkswagen AG d
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at
4.3.1 Removing
om
ion
c
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or
– Remove transfer box ⇒ page 304 .

his
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– Undo bolts -arrows- on intermediate flange for front final drive.

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– Dowel pins -A- and magnet -B- remain on intermediate flange.

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Slowly and carefully remove intermediate flange for front final yri
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drive gearbox housing. Otherwise pinions (gear wheels) can drop cop Vo
by lksw
out of gearbox. cted agen
Prote AG.
Gear wheels which have been dropped on the floor must not be
reinstalled. If this happens, gearbox must be renewed.
– Lift off intermediate flange for front final drive.

– Do remove drive pinion -1-, intermediate pinion -2- and input

pinion -3- for front final drive and secure against falling out.
If the front final drive gear wheels (pinions) are removed, the gear
wheel markings -arrows- for output pinion -1- and intermediate
pinion -2- must face outwards (away from gearbox) when rein‐
stalling.
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4.3.2 Installing
itte
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following:
is n
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ole,
– Ensure dowel sleeves -A- are seated correctly before instal‐
spec
ling.
t to the co
– Fit new gasket -B-.
– Place on intermediate flange for front final drive.
rrectne
Take great care when fitting intermediate flange to output shaft to
avoid damaging sealing lips of seal -arrow-.
ss o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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– Tighten the bolts -arrows- on intermediate flange for front final

iv
o
pr
drive hand-tight.
um
r
fo
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t.
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– Ensure dowel pins -A- and magnet -B- are seated correctly.
Co
Cop py
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– Install transfer box ⇒ page 304 .
ht
pyri by
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cted agen
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– Screw in bolts -A- and -C- for transfer box -2- and tighten fin‐
ger-tight.
– Tighten bolts -B- for front final drive and intermediate flange
-1- and bolts -A- for transfer box -2- in stages and diagonal
sequence to prescribed torque ⇒ Item 30 (page 302) .
– Tighten bolts -C- for transfer box to intermediate flange to pre‐
scribed torque ⇒ Item 12 (page 301) .
– Fill with ATF and check ATF level ⇒ page 151 .
4.4 Renewing seal in intermediate flange for

front final drive
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Special tools and workshop equipment
by
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♦ Thrust piece - 3404- oris tee
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An inspection hole is provided on the left side of the intermediate

nform
flange to check for leaks in the seals at the input pinion and in the
ercia
intermediate flange.
m
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tion in
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4.4.1 Removing
– Remove intermediate flange for front final drive ⇒ page 310 .
– Drive seal out, towards transfer gearbox, using a drift.

4.4.2 Installing
following:
– Check seal seat in intermediate flange for damage and rework
if necessary.
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– Slide oil seal, with open side -arrow- leading, uonto
tho thrust piece
r eo
- 3404- . ss
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– Drive in oil seal with thrust piece - 3404- to stop.
nl
pt
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an
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– Install intermediate flange for front final drive ⇒ page 310 .
erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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m
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thi
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4.5 Renewing oil seal in input pinion
sd
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An inspection hole is provided on the left side of the intermediate

flange to check for leaks in the seals at the input pinion and in the
intermediate flange. gen AG
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4.5.1 Removing
es, in part or in w
t to the co
– Remove intermediate flange for front final drive ⇒ page 310 .
rrectness of i
– Take intermediate pinion -2- for front final drive off gearbox
l purpos
housing.
nform
– Pull input pinion -3- off output shaft.
mercia
Gear wheels which have been dropped on the floor must not be
at
om
io
reinstalled. If this happens, gearbox must be renewed.
n
c
in t
or
his
Output pinion -1- remains on pinion shaft.
ate
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– Drive seal out with a drift.
um
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en
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t.
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4.5.2 Installing
following:
grease - G 052 128 A1- .
– Slide oil seal onto thrust piece - 3403- .
– Drive oil seal in with thrust piece - 3403- onto thrust piece stop.
The contact surface -A- of thrust piece must lie on the input pinion
-B-.

– Cover splines on end of shaft -arrow- completely with adhesive

tape, ensuring there are no folds or butt ends, so that seal is
not damaged when sliding on input pinion.
– Fit input pinion, centring it on output shaft. Installation position:
⇒ Item 34 (page 303) .
Take great care when fitting input pinion to avoid damaging seal‐
ing lips of seal.
– Slide input pinion -3- together with intermediate pinion -2- onto
stop (tapered roller bearing seat) in gearbox housing.
Note installation position of gear wheels (pinions):
Gear wheel markings -arrows- point away from gearbox.
– Install intermediate flange for front final drive ⇒ page 310 .
4.6 Renewing needle bearing for gear

wheel 2
AG. Volkswagen AG d
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rrectness of i
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AG. Volkswagen AG d
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Passat 1997 ➤ , Passat Variantth1997
oris
➤ eo
u
ss a drive 01V - Edition 04.2013 ra
c
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equipment required
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spec
♦ Fitting sleeves for oil seal -
2080 A- urposes, in part or in wh
t to the co
♦ Hot air blower -
V.A.G 1416-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pyri by
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o
by c lksw
cted agen
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♦ Internal puller - Kukko 21/2-

♦ Counter support - Kukko 22/1-
4.6.1 Removing

– Unbolt rear flange shaft, securing flange shaft against turning.
AG. Volkswagen AG d
agen oes
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– Pull tensioning nut -A- out of shaft for gearhowheel
ris 2. nte
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a
– Remove bolts -arrows-. ss c
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un
pt
– Remove guide plate -B- and disc -C-.
an
d
itte
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ility
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spec
t to the co
rrectness o
cial p
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mer
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om
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c
i
or
n thi
– Fit counterhold -A- onto internal puller-B- as shown and fit onto
te
sd
a
shaft of gear wheel 2.

iv
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pr
cum
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-A- - Counter support - Kukko 22/1- en

ng
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-B- - Internal puller - Kukko 21/2-
C py
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– Support counterhold -A- with thrust plate - VW 402- and pre‐ cop Vo
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tension counterhold using nut -1-.
cted agen
Prote AG.
– Pull out gear wheel and take out carefully upwards.

– Remove securing ring for needle bearing.

– Move centring sleeve -2- of internal puller -item B- about 4 mm

in direction of arrow so that hooks of internal puller can be
opened wide enough.
The upper part of the illustration shows how the extractor hooks
on internal puller -B- must be inserted in the needle bearing.
-A- - Counter support - Kukko 22/1-
-B- - Internal puller - Kukko 21/2-
– Spread internal puller -B- into upper lip of the needle bearing
-1- and tighten internal puller with nut.
– Fit counterhold -A- onto internal puller -B- as shown.

– Support counterhold -A- with thrust plate - VW 402- and pre‐
tension counterhold using nut -3-.
– Quickly heat exterior of transfer box housing in area of needle
bearing seat to approx. 80 to 100 °C with hot air blower -
V.A.G 1416- .
WARNING
AG. Volkswagen AG d
agen oes
Wear protective gloves!y Volksw not
gu
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th
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– Pull needle bearing
ss out quickly. c
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un
pt
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rm
ab
pe
ility
ot
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, is n
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hole
spec
4.6.2 Installing
es, in part or in w
t to the co

following:
rrectness of i
– Check needle bearing seat in transfer housing for damage and

rework if necessary.
l purpos
– Quickly heat exterior of transfer box housing in area of needle

bearing seat to approx. 80 to 100 °C with hot air blower -
nform
ercia
V.A.G 1416- .
m
a
com
tion in
WARNING
r
te o
thi
s
iva
do

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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place new needle bearing in position and fit fitting sleeve for
oil seal - 2080 A- onto new needle bearing -1-.
The sleeve must be centred on the fitting sleeve.
– Drive needle bearing into transfer box housing flush to stop
with press tool - VW 408 A- .
– Install securing ring for needle bearing.
AG. Volkswagen AG d
– Insert gear wheel 2 carefully. ksw
agen oes
not
Vol
by gu
d ara
rise nte
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ss c
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du
an
itte
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ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Insert guide plate -B- and disc -C- and secure with bolts
-arrows- ⇒ Item 22 (page 302) .
rrectness of i
– Press tensioning nut -A- into shaft of gear wheel 2.
l purpos
– Install rear flange shaft ⇒ Item 1 (page 301) .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
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en
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Cop py
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gh ht
pyri by
Vo
co lksw
by
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Prote AG.

K0550662920-5-Speed Automatic Gearbox Four-Wheel Drive 01V

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K0550662920-5-Speed Automatic Gearbox Four-Wheel Drive 01V

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0550662920

1.1 Connecting tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3 Checking operation of the ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.6 Assembly overview - dismantling and assembling selector mechanism . . . . . . . . . . . . . . 38

3.8 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 49

3.9 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.10 Removing and installing locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.11 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4 Removing, dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . 59

4.1 Assembly overview - Dismantling and assembling selector mechanism cover . . . . . . . . . . 59

4.2 Removing and installing selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.3 Dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.7 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

7.2 Position of selector elements with hydraulic control E18/2 . . . . . . . . . . . . . . . . . . . . . . . . 160

8 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

2.1 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2 Repairing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

2.1 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

2.2 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

2.3 Replacing front final drive/gearbox housing sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . 289

2.4 Renewing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

3 Axle oil in transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

3.1 Checking axle oil in transfer box and replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

4 Repairing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

4.2 Renewing seal for rear flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

4.5 Renewing oil seal in input pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

4.6 Renewing needle bearing for gear wheel 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

1.1 Gearbox identification

1.1.1 Location of codes on gearbox

The gearbox code also appears on the vehicle identification

2 Notes on 5-speed automatic gearbox

2.1 Notes on 5-speed automatic gearbox

2.1.1 Torque converter

The gear change point, which is dependent on the driving situa‐

2.1.4 Gear change point variations for grades

An additional gear change map automatically selects gear tion in

changes for gradients dependent upon accelerator pedal position

and driving speed.

• Gear change map for extreme uphill stretches is matched to

2.1.5 Guided fault finding, vehicle self-diag‐

2 Rep. gr.00 - Technical data

3 Codes, engine allocations AG. Volkswagen AG d

Torque converter Identification code N28 K36 F31

using ⇒ Electronic parts catalogue (ETKA) .

For information about this, refer to ⇒ page 24

Automatic gearbox 5-speed 01V four-wheel drive

Gearbox Identification code DST ECB EKD

Manufactured fro 05.97 09.99 08.99

m 05.01 08.00 08.00

Automatic gearbox 5-speed 01V four-wheel drive

Automatic gearbox 5-speed 01V four-wheel drive