1995-1996 Volkswagen Automatic Transmission 01M Service & Repair Manual

AUTO TRANS OVERHAUL - TYPE 01M Article Text 1996 Volkswagen Passat This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru ARTICLE BEGINNING AUTOMATIC TRANSMISSIONS Volkswagen Type 01M - Auto Trans. Overhaul Cabrio, Golf, Golf III, GTI Jetta, Jetta III, Passat APPLICATION & LABOR TIMES APPLICATION & LABOR TIMES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Vehicle Labor Times Trans. Application (1) R & I (2) Overhaul Model 1995-96 Cabrio ............... 4.4 ......... 6.3 .... 01M (CLK) Golf, GTI & Jetta 4-Cylinder Gas ................. 4.4 ......... 6.3 .... 01M (CLK) Turbo Diesel ........ 4.4 ......... 6.3 .... 01M (CKZ) V6 ................... 4.4 ......... 6.3 .... 01M (CLB) Passat 4-Cylinder Gas ................. 4.9 ......... 6.3 .... 01M (CLK) Turbo Diesel ........ 4.9 ......... 6.3 .... 01M (CKZ) V6 ................... 4.9 ......... 6.3 .... 01M (CLB) (1) - Removal and installation of transmission from vehicle chassis. (2) - On bench overhaul for transmission and differential. DOES NOT include removal and installation. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IDENTIFICATION Volkswagen Audi Group (VAG) transaxle type is cast into top of transaxle case, next to ATF cooler. Transaxle code and build date are located on top of transaxle case, next to starter. DESCRIPTION & OPERATION Transaxle includes a 4-speed automatic transmission, lock-up torque converter, final drive and solenoid-operated valve body. See Fig. 1. Under normal conditions, all shifts are controlled by a Transaxle Control Module (TCM). See Fig. 2. Fourth gear is an overdrive gear.

Fig. 1: Cross-Sectional View Of Transaxle Components Courtesy of Volkswagen United States, Inc. Fig. 2: Identifying TCM & Shift Lock Electrical Components Courtesy of Volkswagen United States, Inc.

The transmission elements consist of a planetary gear set, one-way roller clutch, 3 apply clutches, 2 brake clutches and a torque converter lock-up clutch. See Figs. 1 and 3. All 4 forward gears are hydraulically activated. When the lock-up clutch is engaged, the forward gears become mechanically driven by eliminating torque converter slip. The lock-up clutch is engaged depending on engine load and vehicle speed. Power from the transmission is connected to the drive pinion through transfer gears. A ring gear and differential assembly are connected to flanges which spin the drive axles. The electronic control consists of a TCM (located under rear seat), control solenoids, various sensors and switches. The control solenoids direct oil pressure inside the valve body. Solenoid valves No. 1-4 control the apply and brake clutches. Solenoid valves No. 5 and 7 control shift smoothness. Solenoid valve No. 6 is a frequency valve and controls the main hydraulic pressure. The TCM controls the main hydraulic pressure by varying the duty cycle. The TCM monitors input and output signals. If electrical problems occur, TCM will record faults in TCM memory and may go into fail-safe mode (also known as emergency running mode). If TCM enters fail-safe mode, the transaxle will operate manually in reverse, 1st or 3rd gear. In fail-safe mode, 3rd gear operates with gear selector in 2nd, 3rd or "D". If engine is started with TCM in fail-safe mode, TCM activates 3rd gear hydraulically. The TCM memory can only be read using Scan Tool (VAG 1551) and Adapter (VAG 1551/3). The TCM also controls shift lock system. This system locks the gear selector in Park or Neutral position unless the brake pedal is pressed. The TCM uses a shift lock control relay to release a gear- selector mounted solenoid. See Fig. 2. Fig. 3: View Of Transaxle Clutch Elements Courtesy of Volkswagen United States, Inc. LUBRICATION & ADJUSTMENTS

NOTE: See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING section. TROUBLE SHOOTING SYMPTOM DIAGNOSIS Leak At Torque Converter Check drive plate clearance, torque converter bushing, oil seal or oil pump assembly. Repair as necessary. Transaxle Fluid In Coolant Faulty transaxle oil cooler. Replace transaxle oil cooler and friction plates in transaxle. Clean transaxle. Transaxle & Differential Oils Mixed Replace "O" ring and drive pinion seal on inner bearing support. Gear Selector Hard To Move Check gear selector between shifter and transaxle. Repair as necessary. Check parking lock assembly inside transaxle. Repair as necessary. No Drive In 1st Gear Check for faulty 1st-3rd apply clutch or reverse brake clutch. No Drive In "D", "2" Or "3" Check for faulty 1st-3rd apply clutch or one-way clutch. No 2nd Gear In "D", "2" Or "3" Check for faulty 2nd-4th brake clutch. No 3rd Gear In "D" Or "3" Check for faulty reverse apply clutch. No 4th Gear In "D" Check for faulty 2nd-4th brake clutch. No Reverse Check for faulty reverse apply clutch or reverse brake clutch. No Drive In All Forward Gear Positions Check for faulty 1st-3rd apply clutch, reverse brake clutch or one-way clutch. Missing Shifts Up Or Down Check valve body for sticking valve(s) or faulty shift solenoid(s).

Erratic Or Harsh Shifts Short in wiring to shift solenoid(s) or faulty shift solenoid(s). Check for proper throttle angle adjustment. See TECHNICAL SERVICE BULLETINS. Harsh Shift In One Gear Only Determine elements involved. Air check elements. Check for faulty shift solenoid or shift valve. Stuck In Emergency Running Mode Check for incorrect TCM installed, faulty wiring, bad solenoid electrical strip (inside oil pan) or stuck valve. Park Lock Will Not Engage Check for misadjusted selector lever cable. Check for faulty locking mechanism. Bucking Or Poor Idling Check throttle housing and air ducts for leaks. Check for possible air entering oil pump pickup. Excess Engine RPM Drop When Shifting Into 1st Gear Faulty Powertrain Control Module (PCM). Engine Starts In Gear Or No Start In Park/Neutral Check for faulty Park/Neutral safety switch. Shift Lock Not Holding Selector In Park/Neutral Check for faulty shift lock solenoid, shift lock mechanism or bad TCM. MECHANICAL, HYDRAULIC & ELECTRICAL COMPONENTS 1) If gear selector is stuck in Park or Neutral position, go to SHIFT LOCK SYSTEM under TROUBLE SHOOTING. If gear positions are missing, shift quality is poor or no shifts are possible, ensure all electrical connections are okay and fluid level is correct. 2) If problems are still present, disconnect electrical connector at transaxle. Test drive vehicle. Check if transaxle will operate manually in reverse and 1st gear. Move gear selector to 2nd, 3rd or "D" position. Transaxle should operate in 3rd gear (2nd, 3rd or "D"). 3) If transaxle operates as described, problem may be electrical. See ELECTRONIC SELF-DIAGNOSTICS. If transaxle does not operate as described, problem may be mechanical or hydraulic. See ROAD TEST. NOTE: If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear.

ROAD TEST WARNING: DO NOT exceed safe or legal speed limits during road test. 1) Road test vehicle with transaxle in "D" range. With vehicle at a speed above kickdown speed, press throttle pedal down and note kickdown shift speeds. Compare kickdown shift speeds to kickdown shift speed specifications. See KICKDOWN SHIFT SPEED SPECIFICATIONS table. NOTE: In the following table, letter suffix following gear application refers to Hydraulic ("H") or Mechanical ("M") gear operation. Hydraulic or manual gear operation depends on operating mode of torque converter lock-up clutch. KICKDOWN SHIFT SPEED SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Kickdown (MPH) 4-Cylinder (CLK) 1H-1M ............................................ 30-34 1M-2H ............................................ 30-34 2H-2M ............................................ 61-65 2M-3H ............................................ 61-65 3H-3M ............................................ 85-89 3M-4H ............................................ 85-89 4H-4M ............................................ 85-89 4M-4H ............................................ 86-83 4H-3M ............................................ 86-83 3M-3H ............................................ 61-57 3H-2M ............................................ 61-57 2M-2H ............................................ 61-57 2H-1M ............................................ 26-22 1M-1H ............................................ 26-22 Turbo Diesel (CKZ) .................................. (1) V6 (CLB) 1H-1M ............................................ 37-41 1M-2H ............................................ 37-41 2H-2M ............................................ 76-80 2M-3H ............................................ 76-80 3H-3M .......................................... 111-115 3M-4H .......................................... 111-115 4H-4M .......................................... 111-115 4M-4H .......................................... 112-108 4H-3M .......................................... 112-108 3M-3H ............................................ 75-71 3H-2M ............................................ 75-71 2M-2H ............................................ 75-71 2H-1M ............................................ 32-28 1M-1H ............................................ 32-28 (1) - Information not available from manufacturer. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

2) Connect scan tool and appropriate adapter to diagnostic connector. Select function 08 "READ MEASURING VALUE BLOCK". Test solenoid valves and upshift speeds following scan tool manufacturers instructions. 3) If transaxle does not shift within specified MPH range, and scan tool values are within specification, determine affected elements. See APPLY & BRAKE CLUTCH APPLICATION. 4) If all apply and brake clutch elements are affected, check oil pump, oil filter, cooler lines, solenoid valve No. 6, and condition of torque converter and/or engine. Repair as necessary. 5) If one or more apply and brake clutch elements are affected, remove valve body. Locate appropriate fluid circuit in transaxle case and valve body. Check for leaks and/or blockage. Repair as necessary. 6) If hydraulic circuits are okay, or problems with apply and brake clutch elements are mechanical, repair transaxle. NOTE: If transaxle does not operate in manual 1st gear, check 1st-3rd apply clutch and reverse brake clutch for damage or wear. If transaxle does not operate in manual reverse gear, check reverse apply clutch and reverse brake clutch for damage or wear. APPLY & BRAKE CLUTCH APPLICATION APPLY & BRAKE CLUTCH APPLICATION (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Gear Application Elements In Use 1st Gear .......... 1st-3rd Apply & One-Way Clutch Holding 2nd Gear ................... 1st-3rd Apply & 2nd-4th Brake 3rd Gear .................... 1st-3rd & 4th Apply Clutches 4th Gear ....................... 4th Apply & 2nd-4th Brake Reverse .................... Reverse Apply & Reverse Brake Park & Neutral ................ All Apply & Brake Clutches Released Or Ineffective (1) - All forward gear elements shown are in "hydraulic-state". Forward gear elements switch to a "mechanical-state" with the addition of torque converter lock-up clutch apply. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT LOCK SYSTEM Operation All models are equipped with an electronic shift lock system. TCM controls shift lock system. See Fig. 2. This system locks gear selector in Park or Neutral position unless brake pedal is pressed. TCM uses shift lock control relay to release a solenoid mounted on gear selector assembly.

NOTE: Shift lock relay will not lock gear selector when vehicle speed is greater than 3 MPH. A mechanical control cable prevents ignition key from being removed unless gear selector is in Park position. With ignition key removed, gear selector locks in Park position. NOTE: If battery is disconnected or discharged, gear selector can be moved out of Park position by turning ignition key to START position. Functional Check 1) With ignition key removed, ensure gear selector cannot be moved from "P" position. Insert key in ignition switch. 2) Turn ignition on. Ensure gear selector can only be moved with brake pedal pressed. Move gear selector to "N" position. 3) Without pressing brake pedal, ensure gear selector cannot move out of "N" position. Press brake pedal down. Ensure it is now possible to move gear selector. 4) If shift lock system does not operate as described, adjust gear selector, solenoid and control cable. If shift lock system does not operate after adjustments are made, check shift lock electrical system with Scan Tool (VAG 1551). 5) See testing information under ELECTRONIC SELF-DIAGNOSTICS. See Figs. 10-13. If any problems are found, service harness or components. If no problems are found, TCM may be defective. If shift lock system still does not operate correctly, check for worn or damaged parts and replace as necessary. See Figs. 2 and 4.

Fig. 4: Exploded View Of Shift Lock & Gear Selector Assembly Courtesy of Volkswagen United States, Inc. NOTE: Perform the following adjustments in order given. Control Cable Adjustment Loosen lock screw at gear selector lever on transaxle. Move gear selector in center console to Park position. Ensure front wheels are locked. Tighten cable housing to gear selector lever lock screw. Shift Lock Solenoid Adjustment Place gear selector in "N" or "P" position. Loosen shift lock solenoid mounting screws. Insert a .019" (.30 mm) feeler gauge between shift lock solenoid push rod and shift lever. See Fig. 5. If necessary, move shift lock solenoid and tighten screws.

Fig. 5: Adjusting Shift Lock Solenoid Courtesy of Volkswagen United States, Inc. Shift Lock Cable Adjustment 1) Move gear selector to "1" position. Remove steering column covers. Turn ignition key to START position and release. Check clearance between shift lock cable lever and ignition switch locking pin. 2) Clearance should be .028" (.70 mm). If clearance is not correct, loosen lock nut on shift lock cable sheath. Position shift lock cable lever to obtain correct clearance. Tighten lock nut. See Fig. 6. Tighten gear selector housing screws and install steering column covers. Fig. 6: Adjusting Shift Lock Cable

1995-1996 Volkswagen Automatic Transmission 01M Service & Repair Manual

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