Install Cover

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 2006 Volkswagen Golf, 2006 Volkswagen GTI, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, and 2005 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Clean sealing surfaces with cleaning solution D 009 401 04 .

NOTE:

Sealing surfaces must be absolutely free of oil and grease. Leaks may otherwise result.

Fig 1: Attaching Thrust Washer In Cover With Petroleum Jelly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attach thrust washer in cover with petroleum jelly (e.g. Vaseline).

The cover must be sealed against transmission with sealant D 176 404 A2 .

Fig 2: Applying A Bead Of Sealant To Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply a "3 mm wide" bead of sealant to transmission housing as shown in figure.

Fig 3: Attention (Applying A Wider Bead With Good Intention Does Not Seal Better, But Rather Leads To Malfunctions)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Applying a wider bead with good intention does not seal better , but rather leads to malfunctions.

Set transmission housing cover in place.

Fig 4: Identifying Transmission Housing Cover Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

First start only bolts - 1 - and - 2 - and hand tighten.

This way the rubber rings under bolts - 1 - will find optimal seat in cover.

Start all other bolts by hand and tighten down to cover.
Tighten two bolts - 1 - to 35 Nm.
Then tighten bolt - 2 - to 20 Nm.
Finally tighten remaining bolts to 20 Nm.
Turn transmission.
Install brake band "3".

Fig 5: Assuring Proper Seating In Catch And Plunger

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assure proper seating in catch - 1 - and plunger - 2 -.

Fig 6: When Installing Clutch "K4", Raise Brake Bank Slightly With A Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When installing clutch "K4" , raise brake bank slightly with a wire.
Insert needle thrust bearing - 1 -.

Fig 7: Installing Gear -A- With Retaining Ring Downwards

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install gear - A - with retaining ring downwards.
Align inner plates of "K4".

Fig 8: Now Pick Up Planetary Gear Set III

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Now pick up planetary gear set III.

Fig 9: Inserting It Far Enough That Spur Gears Engage

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert it far enough that spur gears engage.

Fig 10: Turning It Back And Forth Until Two Spur Gears Are In The Same Plane

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn it back and forth until two spur gears are in the same plane.

The turning back and forth thread the plates into plate carrier.

It is best to use a T-bar with a 32 mm socket.

Fig 11: Installing Turbine Shaft -A-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install turbine shaft - A -. Turn shaft back and forth and push into transmission to stop.

The shaft is correctly installed if the lower shoulder - arrow - of shaft contacts spur gear.

There must be no seal in groove - 1 - of turbine shaft during installation of the ATF pump. Remove it first.
Lay gasket - B - for ATF pump on pump flange.
Install ATF pump and ATF strainer and tighten bolts to 20 Nm.

Fig 12: Identifying If There Is Still A Seal In Groove

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If there is still a seal in groove - 1 - remove it.

Fig 13: Inserting Differential Cage -A- And Then Needle Thrust Bearing -B-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Next insert differential cage - A - and then needle thrust bearing - B -.

Two versions of gasket - C -

Fig 14: Measuring Thickness Of Mounting Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Measure thickness of mounting plate.

Two different thicknesses of gaskets are included in repair component.

Fig 15: Installing Gasket -C- Having Same Thickness As The Gasket Which Was Removed

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install gasket - C - having same thickness as the gasket which was removed.
Install new seal - 1 - for ATF pump.

Then clean torque converter housing.

Clean sealing surfaces with cleaning solution D 009 401 04 .

NOTE:

Sealing surfaces must be absolutely free of oil and grease. Leaks may otherwise result.

The torque converter housing may be installed after it is cleaned.

The torque converter housing must be sealed using sealant D 176 404 A2 .

Fig 16: Cutting Off Tube Nozzle & Applying Silicone Sealing Compound To Transmission Housing Sealing Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply a "3 mm wide" bead of sealant to transmission housing as shown in figure.

Fig 17: Attention (Applying A Wider Bead With Good Intention Does Not Seal Better, But Rather Leads To Malfunctions)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Applying a wider bead with good intention does not seal better , but rather leads to malfunctions.

Set torque converter housing in place.
Tighten all 21 bolts by hand.
Tighten bolts diagonally to 28 Nm.