Technical Service Information This manual covers both the model 003 and model 010 transmissions. The model 003 first appeared in Fastback and ‘Squareback Volkswagon 1968-1973 and in some Audi models. The model 010 unit first appeared in 1972 Volkswagon Rabbits, and Scirocco and in Audi vehicles. | | | We thank Volkswagon for the information and illustrations that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT WAYNE COLONNA. ED KRUSE TECHNICAL SUPERVISOR ‘TECHNICAL CONSULTANT PETER LUBAN JIM DIAL, ‘TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT GREGORY LIPNICK JERRY GOTT ‘TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT DAVID CHALKER ARSENIO RIVERA ‘TECHNICAL CONSULTANT ‘TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP. 9200 S. DADELAND BLVD. SUITE 720 4 MIAMI, FLORIDA 33156 (305) 670-4161ATSG INDEX GENERAL DESCRIPTION ........ TROUBLESHOOTING (003) PRESSURE STESTINGH ess: suite ca : ON-CAR REPAIR .. TEAROOWN (003) . FINAL ORIVE .. SPECIFICATIONS ..... TEAROOWN (010) FINAL ORIVE AUTOMATIC TRANSMISSION SERVICE GROUP@4ATSG Technical Service Information 1, GENERAL DESCRIPTION ‘The automatic transmission is housed in a case as- ‘sembled from two main castings. At the front of the as- sembly is a cast aluminum transmission case containing ‘the automatic transmission fluid (ATF) pump, the hydrau- lic controis, anc the planetary gear system. Attached at the rear of this case by four steel studs is a final drive housing cast in light magnesium alloy. The drive pinion, ring gear. and differential assembly are mounted on pered-roller bearings in a separate cast iron car bolted inside the magnesium casting. The bellhousing for the torque converter is an integral part of the final drive housing Torque Converter The torque converter is a large doughnut-snaped as- ‘sembly located between the engine and the automatic transmission. The converter not only receives engine out- but and passes it on to the transmission, but also multi- plies engine torque at low vehicle speeds and serves as a fluid coupling between the engine and the transmission. ‘The converter housing spins with the engine's crank- shaft. Curved vanes inside the housing set up a flow of ATF that drives another vaned wheel called the turbine ‘The turbine drives a hollow shaft that transmits power to the transmission ATF Pump. ATE must be circulating under pressure before the au- tomatic transmission can function. The ATF pump that Creates this pressure is located at the extrome front of the tansmission case. A long pump driveshaft that passes ‘through the center of the hollow turbine shaft drives the ATF pump. ‘The pump driveshaft is splined directly into the con- verter housing. The pump therefore circulates ATF when- ever the engine is running, regardless of selector lever Position. Since circulating ATF is also the transmission’s only lubricant, itis important to remember that ATF does Not circulate when the engine is not running and the car is being towed. cauTion— "Naver fow a ear with automatic vansmiesion faster than 30 mph (8 kph) or farther than 30 ‘niles (48 kilometers). Bearings can be dam- ‘aged by lack of lubrication. if you must tow ‘he car farther, lit the rear wheels or remove ‘the rear whee! diveshats that connect the ‘rear whoels tothe trenemiesion, Planetary Gears A torque converter alone cannot supply the torque ‘multiplication needed for all driving conditions. The out- put of the torque convertor is therefore routed into a plan- ‘tary gearset. The planetary gearset is located at the rear ff the transmission case, just ahead of the final drive housing. ‘The planetary gear system used in the VW automatic transmission operates on the same principles as similar ‘gearsets found in other automatic transmissions but dit {ers in numerous construction details. The planetary gear system has one large sun gear (51 teeth), one small sun ‘gear (30 teeth), three small planet pinions (16 teeth each), three large planet pinions (35 teeth each), and one large annulus (fing) gear. The planet pinions are all mounted ‘on the planet carrier which is coupled to the final drive pinion (transmission output shaft). The annulus has a ‘one-way roller clutch to provide free wheeling when the driver takes his foot off the accelerator with the selector lever at D and the transmission in tst gear. Clutches ‘Two hydraulically operated multiple disk clutches con- trol the delivery of turbine output to the planetary gear system. The clutch at the front of the transmission is callod the direct and reverse clutch because it transfers power to the small sun gear of the planetary gearset only when the transmission is in direct (3rd gear) or in reverse. The other clutch, located between the direct and reverse clutch and the planetary gearset, is called the forward clutch because it transfers power to the large sun gear in all forward gears. Brake Bands Two hydraulically operated brake bands are used to hold various parts of the planetary gear system stationary, thereby obtaining reverse and 2nd gears. One brake band ‘operates on the outer surlace of the planetary gearset annulus (ring) gear. Its called the Ist and reverse brake ‘band because its purpose is to provide reverse operation land to keep the transmission trom freewheeling in 1st ‘gear when the solector lever is in 1. This brake band does ‘not engage when the transmission is in tst gear and the solactor lever is at D. ‘The other brake band locks the drum that houses the direct and reverse clutch and thereby prevents free rota- tion of the small sun gear in the planetary gearset. It is called the 2nd gear brake band because itis applied in ‘2nd gear with the selector lever at D or at2, or during 2nd ‘gear kickdown. Both brake bands are fitted with adjusting Screws. However, adjustments can be performed only af= tor the transmission has been removed from the car