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Volkswagen 01M Transmission. Manual - part 58

Technical Service Information

COMPONET REBUILD (CONT'D)

VALVE BODY ASSEMBLY

A-3

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

9AN

017

K01

762

8BA

3K0

9AN

01748

9AN3K

01742

4AM3K03O1

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

     1. Lay the valve body assembly on a flat work
surface, as shown in Figure 167.
     2. Remove the seven bolts retaining the manual
             valve body, as shown in Figure 167.
     3. Remove the manual valve body and manual
valve, as shown in Figure 167.
     4. Turn the valve body assembly over, as shown
in Figure 168.
     5. Remove the 39 upper to lower valve body
bolts, as shown in Figure 168.
Note: There are three different lengths of
these bolts See Legend in Figure 168.
     6. Remove the two oil baffles, as shown in
Figure 168.
     7. Seperate the upper valve body, spacer plate
and lower valve body.

Figure 168

Figure 167

770 MANUAL VALVE.
771 MANUAL VALVE BODY CASTING.
772 MANUAL VALVE BODY RETAINING BOLT, 38 MM (1.496") (7 REQ).

668 UPPER VB TO LOWER VB BOLT, 22 MM (.866") (4 REQUIRED).
669 UPPER VB TO LOWER VB BOLT, 28 MM (1.102") (25 REQUIRED).
670 UPPER VB TO LOWER VB BOLT, 40 MM (1.574") (10 REQUIRED).
671 OIL BAFFLE NUMBER 2.
672 OIL BAFFLE NUMBER 1.

770

668

669

670

671

672

771

772

Continued on Page 92

Special Note: This valve body has proven to have
very high bore wear and Sonnax® has available
several line-ups that may save you from having to
purchase a new valve body.

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

4AM

3K0

3O18

K0176

9AN3

1755

A3K0

1631

9AN3K

01748

N3K

01742

"09D" LOWER VALVE BODY, EXPLODED VIEW

600

601

602

603

604

605

606

607

608

609

610

611

612

613

614

616

617

618

619

620

621

622

625

624

625

626

627

628A

629

630

631

632

633

634

635

636

637

638

639

640

641

642

643

644

645

646

647

648

649

650

651

652

653

654

655

656

657

658

628B

615

VALVE BODY ASSEMBLY (CONT'D)

     8. Disassemble lower valve body and place valves,
             springs, bore plugs and retainers on appropriate
trays exactly as they are removed, as shown in
             Figure 169. Small parts are shown in Figure 172.
Note: Tag the "Linear" solenoid locations on
removal, as they are position sensitive.
     9. Clean all lower valve body parts thoroughly and
dry with compressed air.
Note: Do not submerge solenoids in solvent.

Continued on Page 93

Figure 169

Technical Service Information

See Legend Figure 170

ADJUSTABLE

PLUG

ADJUSTABLE

PLUG

9
AN3

6
2

Note: Measure

Plug depth before

plug is removed

Caution:
There are 4 adjustable plugs screwed into the valve
body casting at the end of the clutch regulating bores,
as shown in Figure 169, along with two clips that are
not necessary to remove. If removal does become
necessary, measure plug depth before plug is removed
as it is a critical adjustment.

600 LOWER VALVE BODY CASTING.
601 SECONDARY PRESSURE REGULATOR VALVE.
602 SECONDARY PRESSURE REGULATOR VALVE SPRING (RED).
603 SECONDARY PRESSURE REGULATOR VALVE ADJUSTMENT PLUG.
604 SECONDARY PRESSURE REGULATOR VALVE ADJUSTMENT RETAINER.
605 NUMBER 1 REL AY VALVE.
606 NUMBER 1 REL AY VALVE SPRING (NONE).
607 NUMBER 1 REL AY VALVE RETAINER.
608 N93 P WM LINE PRESSURE CONTROL SOLENOID.
609 N92 P WM K1 CLUTCH CONTROL SOLENOID.
610 N90 P WM K3 CLUTCH CONTROL SOLENOID.
611 N283 P WM B1 CLUTCH CONTROL SOLENOID.
612 N282 P WM K2 CLUTCH CONTROL SOLENOID).
613 P WM SOLENOID RETAINER PINS (6 REQUIRED).
614 K1 CLUTCH REGULATOR VALVE SPRING (RED).
615 K1 CLUTCH REGULATOR VALVE.
616 K3 CLUTCH REGULATOR VALVE SPRING (NONE).
617 K3 CLUTCH REGULATOR VALVE.
618 B1 CLUTCH REGULATOR VALVE SPRING (NONE).
619 B1 CLUTCH REGULATOR VALVE.
620 K2 CLUTCH REGULATOR VALVE SPRING (NONE).
621 K2 CLUTCH REGULATOR VALVE.
622 N89 ON/OFF SOLENOID.
624 N91 P WM TCC CONTROL SOLENOID PIN RETAINER.
625 RETAINING BOLTS, 12 MM (0.472") LONG (6 REQUIRED).
626 TRANSMISSION TEMP SENSOR RETAINING BRACKET.
627 N93, N90, N92, N283, N282 SOLENOID PIN RETAINER.
628A B2 PRESSURE SWITCH   (NOT USED IN ALL MODELS).
628B K1 PRESSURE SWITCH   (NOT USED IN ALL MODELS).
629 N88 ON/OFF SOLENOID.
630 K2 ACCUMULATOR PISTON.
631 K2 ACCUMULATOR PISTON OUTER SPRING (NONE).
632 K2 ACCUMULATOR PISTON INNER SPRING (GRAY).
633 K2 ACCUMULATOR PISTON BORE PLUG.
634 K2 ACCUMULATOR PISTON BORE PLUG RETAINER.
635 B1 ACCUMULATOR PISTON.
636 B1 ACCUMULATOR PISTON OUTER SPRING (NONE).
637 B1 ACCUMULATOR PISTON INNER SPRING (GRAY).
638 B1 ACCUMULATOR PISTON BORE PLUG.
639 B1 ACCUMULATOR PISTON BORE PLUG RETAINER.
640 FORWARD ENGAGEMENT ACCUMULATOR SPRING NONE).
641 FORWARD ENGAGEMENT ACCUMULATOR PISTON.
642 FORWARD ENGAGEMENT ACCUMULATOR BORE PLUG.
643 FORWARD ENGAGEMENT ACCUMULATOR BORE PLUG RETAINER.
644 K1 SWITCH VALVE SPRING (PINK).
645 K1 SWITCH VALVE.
646 K1 SWITCH VALVE BORE PLUG.
647 K1 SWITCH VALVE BORE PLUG RETAINER.
648 N91 P WM TCC CONTROL SOLENOID.
649 N93/LINE PRESSURE SOLENOID ACCUMULATOR PISTON.
650 N93 ACCUMULATOR PISTON OUTER SPRING (NONE).
651 N93 ACCUMULATOR PISTON INNER SPRING (GRAY).
652 N93 ACCUMULATOR PISTON BORE PLUG.
653 N93 ACCUMULATOR PISTON BORE PLUG RETAINER.
654 K3 ACCUMULATOR PISTON.
655 K3 ACCUMULATOR PISTON OUTER SPRING (NONE).
656 K3 ACCUMULATOR PISTON INNER SPRING (GRAY).
657 K3 ACCUMULATOR PISTON BORE PLUG.
658 K3 ACCUMULATOR PISTON BORE PLUG RETAINER.
659 ROUND SCREENS   (OPEN SIDE FACES SPACER PLATE) (2 REQ).
660 VALVE BODY SPACER PLATE.
661 OVAL SCREEN   (OPEN SIDE FACES SPACER PLATE).
662 K3 EXHAUST CHECK VALVE, 9.96 MM (.392") DIAMETER.
663 K3 EXHAUST CHECK VALVE SPRING   (WHITE).
664 REGUL ATED EXHAUST CHECK VALVE, 9.96 MM (.392") DIA.
665 REGUL ATED EXHAUST CHECK VALVE SPRING (WHITE).
666 B2 CLUTCH PLASTIC CHECK VALVE ASSEMBLY.
667 FORWARD/K2 PLASTIC CHECK VALVE ASSEMBLY.

SPRING NUMBER 602
Free Length = 1.043"
Spring Diameter = .623"
Wire Diameter = .052"
Approx Coils = 6 (RED)

SPRING NUMBER 616
Free Length = .860"
Spring Diameter = .235"
Wire Diameter = .032"
Approx Coils = 13 (NONE)

SPRING NUMBER 618
Free Length = .860"
Spring Diameter = .235"
Wire Diameter = .032"
Approx Coils = 13 (NONE)

SPRING NUMBER 620
Free Length = .860"
Spring Diameter = .235"
Wire Diameter = .032"
Approx Coils = 13 (NONE)

SPRINGS 631, 636, 650, 655,
Free Length = 1.085"
Spring Diameter = .628"
Wire Diameter = .082"
Approx Coils = 6.5 (NONE)

SPRINGS 632, 637, 651, 656,
Free Length = 1.093"
Spring Diameter = .430"
Wire Diameter = .062"
Approx Coils = 8.5 (GRAY)

SPRING NUMBER 640
Free Length = 2.456"
Spring Diameter = .775"
Wire Diameter = .075"
Approx Coils = 10 (NONE)

SPRING NUMBER 644
Free Length = 1.090"
Spring Diameter = .280"
Wire Diameter = .025"
Approx Coils = 11 (PINK)

SPRING NUMBER 614
Free Length = 1.018"
Spring Diameter = .235"
Wire Diameter = .025"
Approx Coils = 14 (RED)

SPRING NUMBER 606
Free Length = 1.560"
Spring Diameter = .355"
Wire Diameter = .025"
Approx Coils = 13 (NONE)

LOWER VALVE BODY SPRING SPECIFICATIONS

SPRING NO. 665
Free Length = .600"
Spring Diameter = .248"
Wire Diameter = .023"
Approx Coils = 11 (WHITE)

SPRING NO. 663
Free Length = .600"
Spring Diameter = .248"
Wire Diameter = .023"
Approx Coils = 11 (WHITE)

LOWER VALVE BODY SPRING SPECIFICATIONS

SMALL PARTS, WORM TRACK SIDE

FIGURE 169 AND 172 LEGEND

Technical Service Information

Figure 170

Figure 171

SPECIAL NOTE: VALVE NAMES SHOWN WERE

ASSIGNED BY ATSG BASED ON THEIR FUNCTION.

10. Inspect all lower valve body parts thoroughly for
any wear and/or damage.
Note: See observed spring specs in Figure 171.
11. Assemble the lower valve body parts exactly as
shown in Figure 169, and lube with the proper
ATF as they are installed.
12. Torque the solenoid retaining bracket bolts to
10 N·m (89 in.lb.).

VALVE BODY ASSEMBLY (CONT'D)

Continued on Page 94

ENLARGED VIEW

"09D" LOWER VALVE BODY SMALL PARTS, EXPLODED VIEW

659

660

661

662

663

664

665

666

667

600

Technical Service Information

Figure 172

VALVE BODY ASSEMBLY (CONT'D)
13. Assemble the worm track small parts into lower
valve body exactly, as shown in Figure 172.
14. Disassemble upper valve valve body and place
valves, springs, bore plugs and retainers on
appropriate trays exactly as they were removed,
as shown in Figure 173. Small parts are shown
in Figure 175.
15. Inspect all upper valve body parts thoroughly for
any wear and/or damage.
Note: See spring specs in Figure 176.

         Caution: Solenoid modulator valves (725), (733)
         have high failure rates. Check bores carefully.
         Available from Sonnax®, see Figure 173.
16. Assemble the upper valve body parts exactly as
             shown in Figure 173, and lube with the proper
ATF as they are installed.
Note: Retainer for bore plug 681 will require
             some Trans-Jel® as it is not spring loaded.
17. Install the worm track small parts into the upper
valve body exactly as shown in Figure 175.

Continued on Page 98

See Legend Figure 170

Refer to Page 102 For

Spacer Plate Differences

Between The "2-Port" And

"3-Port" Converters

"A" OR "B"

SPACER PLATE

"A" OR "B"

SPACER PLATE

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

Content .. 56 57 58 59 ..