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Volkswagen 01M Transmission. Manual - part 61

Figure 187

Figure 186

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

AISIN

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

2005-UP UPPER VALVE BODY SIDE VISUAL IDENTIFICATION

Requires The

"K" Spacer Plate

"2-Port" Version

Requires The

"K" Spacer Plate

"2-Port" Version

Requires The

"C" Spacer Plate

"3-Port" Version

Requires The

"C" Spacer Plate

"3-Port" Version

"C" Spacer Style With

Worm Track Changes

Cast With No. "3"

In This Location

"K" Spacer Style With

Worm Track Changes

Cast With No. "AH 5"

In This Location

A-3

AIS

IN 3

1755

9AN3K01762

8BA

3K016

1748

4AM

3K03O18

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

A-3

AIS

H 5

9AN

01762

A3K

016

M3K03O1

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

2005-UP LOWER VALVE BODY SIDE VISUAL IDENTIFICATION

"C" Spacer Style With

Worm Track Changes

Cast With "AISIN 3"

In This Location

"K" Spacer Style With

Worm Track Changes

Cast With "AISIN AH 5"

In This Location

Added Check Valve

Cavity And Retaining

Bracket

Added Check Valve

Cavity And Retaining

Bracket

"8860" Cast

Here

"8860" Cast

Here

"UPDATED" VALVE BODY ASSEMBLY

   Beginning sometime in 2005, Aisin introduced a "new
design" valve body assembly that included hydraulic
improvements, for both the "2-Port" and the "3-Port"
design torque converters.
   This "new design" valve body has an added TCC
exhaust check valve, spring and retainer, as shown in
Figure 186.   We have also included casting number
changes to assist you in visual identification between
the the two new design valve bodies.   The lower valve
body is shown in Figure 186 and the upper valve body is
shown in Figure 187.

   The "new design" valve body also recieved some
hydraulic improvements which required several worm
track changes in both the upper and lower valve body
castings.   This of course also changed the spacer plate
and identification, as it created two new spacer plates to
accommodate the hydraulic changes, plus the "2-Port"
and "3-Port design converters.

103

Technical Service Information

AISIN 3

8 8

6 0

8 8

6 0

8 8

6 0

8 8

6 0

4AM

3K03O1

9AN3K01762

N3K

01755

8BA3K

K01748

N3K01

2005-UP "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

"UPDATED" VALVE BODY INFORMATION (CONT'D)

Continued on Page 106

Figure 188

See Legend Figure 189

Added In

2005-Up Version

See Legend Figure 189

ADJUSTABLE

PLUG

ADJUSTABLE

PLUG

9
AN3

6
2

Note: Measure

Plug depth before

plug is removed

625

777

776

775

We have provided you with an exploded view of the
2005-up lower valve body assembly in Figure 188.
There have also been several small changes to spring
calibrations. The spring identification and all of the
specifications for the 2005-up valve body, are provided
for you in Figure 190.

The valve body assembly process is exactly the same
as previos models and is covered in the valve body
component rebuild section. It is only some internal
components that have changed.

104

Technical Service Information

}

600 LOWER VALVE BODY CASTING.
601 SECONDARY PRESSURE REGULATOR VALVE.
602 SECONDARY PRESSURE REGULATOR VALVE SPRING (NONE).
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 N282 P WM TCC CONTROL SOLENOID PIN RETAINER.
625 RETAINING BOLTS, 12 MM (0.472") LONG (7 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 BORE PLUG.
647 K1 SWITCH 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.
775 TCC APPLY EXHAUST CHECK VALVE ASSEMBLY.
776 TCC APPLY EXHAUST CHECK VALVE SPRING.
777 TCC APPLY EXHAUST CHECK VALVE RETAINER PLATE.

SPRING NUMBER 602
Free Length = 1.025"
Spring Diameter = .640"
Wire Diameter = .055"
Approx Coils = 6 (NONE)

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 = 1.580"
Spring Diameter = .360"
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 188 AND 191 LEGEND

Figure 189

Figure 190

SPECIAL NOTE: VALVE NAMES SHOWN WERE

ASSIGNED BY ATSG BASED ON THEIR FUNCTION.

105

Technical Service Information

"UPDATED" VALVE BODY INFORMATION (CONT'D)

ENLARGED VIEW

2005-UP "09D" LOWER VALVE BODY SMALL PARTS, EXPLODED VIEW

659

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

SMALL MAGNETS

IN BOTTOM OF

ROUND SCREENS

660

661

662

663

664

665

666

667

600

Figure 191

Continued on Page 108

See Legend Figure 189

Shaded Worm Tracks Depict

The Cavitys That Changed

"C" OR "K"

SPACER PLATE

"C" OR "K"

SPACER PLATE

106

Technical Service Information

"UPDATED" VALVE BODY ASSEMBLY (CONT'D)

   The small parts in the lower valve body have not
changed.   Their locations and calibrations are exactly
the same as previous models and are provided for you in
Figure 240.   Notice that several of the worm tracks are
shaded which depict the improvements that have
occured in the hydraulic system. These improvements
also required a change in the spacer plate.

Note: ATSG has available a "Technicians Guide"
that includes color hydraulic schematics for each and
every gear and identification of all orifices and
passages. The 2005-Up valve body hydraulic change
is also included in the "Technicians Guide".

Refer to Page 113 For

Spacer Plate Differences

Between Late "2-Port" And

"3-Port" Converters

Refer to Page 112 For

Hydraulic Improvement

Changes In Spacer Plates

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