DIY Passat B5 gearbox repair

In detail: do-it-yourself repair of the Passat B5 gearbox from a real master for the site my.housecope.com.

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The automatic transmission has gained significant popularity over the past 20 years - after all, this method is much more convenient when driving a vehicle. But also the automatic transmission has its own characteristics in terms of the device, so its repair is a separate topic. The Volkswagen Passat B5 car model sometimes causes difficulties for users in terms of gearbox repair, as it has many features. We will find out further how you can fix the device at home, and in order to dive into the topic in more detail, we look at the do-it-yourself video repair of the Volkswagen Passat B5 automatic transmission.

The first step in general home car diagnostics should be to identify the cause of the breakdown. The most common ones here are:

Leakage of working fluid. If leaks are visible on the unit, in particular in the area of the sealing gum, then the breakdown happened precisely because of this reason. It is almost impossible to avoid this problem, so it is imperative to visually analyze the state of the box at least once a month.
If this problem occurs, the solution may be to replace the gasket and transmission fluid.
Damage to the torque converter. If you have exactly this problem, then it will be possible to repair the automatic transmission Volkswagen Passat B5 with your own hands only with a complete repair of this unit.
Dysfunction can be identified by the following signs: uncomfortable driving, knocking or crackling in the gearbox, loss of dynamics while driving, strong vibrations in motion.
Valve body malfunctions. This problem is very common among those drivers who, before driving in the winter season, do not warm up the car properly and start driving. On new car models, the on-board computer will inform you about this problem. You will also notice it yourself: the car drives with constant shaking, vibration, or refuses to move at all.
Control unit malfunctions. Most often, this problem occurs with relatively old models. The problem manifests itself in the fact that the unit begins to select inappropriate rpm for gear shifting, and it may even block the automatic transmission, which is generally dangerous during the driving period.
In solving such a problem, a complete replacement of some parts of the control unit and its preliminary professional diagnostics can help.

Video (click to play).

After accurately identifying the problem, you can proceed directly to the repair. If you failed to diagnose and the cause of the breakdown is unclear, it is better to take the car to a professional service center.

Home repair of the Volkswagen Passat B5 automatic transmission begins with the removal of the unit. This is not so easy to do, so the topic needs to be given considerable attention. The unit can be removed on ramps, lifts or in special pits. The procedure itself will require wrenches. We remove the gearbox in several stages:

We drain the working fluid, after which we dismantle the pallet.
Disconnect hoses, connectors, pipes, rods.
Remove all screws that support the torque converter.
After that, you need to make sure that nothing is holding the gearbox. Then you can carefully remove it while holding the torque converter.

An important feature of this process is that the box cannot be removed without prior preparation. Otherwise, you can complicate the removal procedure and even damage the vehicle.

Self-repair of an automatic transmission for a Volkswagen Passat B5 consists in a complete disassembly of the box and work with its parts.The parsing is carried out as accurately as possible, according to the following algorithm:

The first detail that appears is the gasket. If it is worn out, then a mandatory replacement is required.
Then we study the couplings. Particular attention must be paid here to the friction discs: they must be replaced if they are worn out or malfunctioning.
Valve body processing. We thoroughly rinse this part. To perform this procedure most effectively, use special brushes and liquid.
We check the pistons for suitability: at this stage, the hydrodynamic transformer oil seal and metal seal rings can also be replaced.
Then you can start assembling the unit: we assemble the brake package using recently replaced parts. We install the valve body, rinse the pallet.
We put the gearbox in place and pour in new gear oil.

This is where the whole repair process ends. For more information, see the video repair automatic transmission Passat B5.

repair of the checkpoint after the intervention of the owner. Pretya transmission takes off.

It seems to me that in order to increase the torque, the drive gear needs to be increased, and the driven gear needs to be reduced. Or, am I wrong?

Pros. The video is short and to the point.

Good day, tell me, the manual transmission is similar, when you turn off the engine from the box, there is a ringing. I'll make a reservation right away, this is not a sound from a flywheel. have thoughts?

Thanks for the video, it helped a lot to repair my box on the Audi A4

good day howls the first and second transmission? why?

the first and second gear turns on with a crunch, which can be a trade wind b5 +

Kind time of the day, tell me, if you please, problems with the box when I turn on the back, sometimes the norms, but in most cases it crunches unpleasantly, sometimes even harshly. what could be? pass b4

Also, the transmission code can be found on the vehicle data plate.

Technical characteristics of manual transmission 0A2 are given in table 7.3.

Removal and installation of the clutch pedal see here
Removal and installation of the clutch master cylinder, see here
Removal, installation and adjustment of the clutch pedal sensor, see here

Removing air from the clutch hydraulic drive is similar to manual transmission 01W / 012, see here
Removal and installation of the clutch slave cylinder similar to manual transmission 01E / 0A1 see here

Removal and installation of the gear lever handle similar to manual transmission 01W / 012 see here

Removal and installation of the gear lever, see here
Removal and installation of rods of the gear change mechanism, see here

Adjustment of the gear change mechanism (see manual transmission 01E / 0A1 here)

Removal and installation of gearbox see here
Removal and installation of the gear shift shaft, see here
Replacement of oil seals of drive shafts, see here

Volkswagen produces reliable, inexpensive cars with German quality and comfort. More and more people around the world are choosing this brand. Since 1999, Volkswagen sales have increased by 20% annually. Since 2009, Volkswagen has been one of the largest car manufacturing companies in the world. The concern consists of more than three hundred companies. Audi, Bentley, Porsche, Skoda, Seat, Bugatti, Lamborghini, Scania - all these are parts of the Volkswagen concern. Cheap Volkswagen car options are popular. In Russia, they are usually brought to technological perfection and do not have "childhood" diseases.

For their cars, Volkswagen uses the usually popular and reliable automatic transmissions. Most of them are able to honestly leave the entire reasonable service life of the car, if, of course, they are serviced on time and are not exposed to unnecessary stress. Volkswagen automatic transmission repair is rarely required, is well studied and does not pose serious problems for service station specialists.

Volkswagen Passat B4 car

For the Passat B4 and Golf model with automatic transmission 096, the following repair features are characteristic:

It is better to order original gaskets and oil seals for Passat B4 and Golf, the rest are of poor quality, except for budget products from Atok.
Rubber pads on pistons lose their properties over time and begin to hold pressure poorly.The entire set of pistons must be replaced or the vehicle has been in service for more than ten years.
As a result of exposure of the hydraulic plate to contaminated oil, the pressure regulator, the torque converter lock-up solenoid, the pressure control valve, and the solenoid valve may fail. After 150,000 runs on the Passat B4, it is necessary to clean the automatic transmission valve body from dirty oil.
After ten years of operation of the Passat B4 and Golf, the properties of the wiring change, the resistance increases and the computer may start giving errors. Therefore, together with the solenoids and sensors, during overhaul, their wiring also changes.
From old age or excessive load, the return springs may fail, which will lead to the inability to engage reverse gear. After ten years, their condition should definitely be checked.

Automatic transmission 096 for Volkswagen Passat B4 and Golf

For the Passat B5 models with automatic transmission 01M, the following repair features are characteristic:

DO NOT SPEND MONEY ON REPAINING!
Now you yourself can remove any scratch from the body of your car in just 5 seconds.

It is better to take only original compression rings for Passat B5. The only analogue is only from the Atok company.
Rubber on the Passat B5 is made of poor quality, in the cold it quickly loses its properties, dries out over time. After a few years, oil begins to leak. At the first sign, you need to change the pistons. This usually applies to machines that have been in operation for more than 10 years.
The sliding bearing on the Passat B5, mounted on the front drum, is made of plastic. Over time, it loses its characteristics and at one point it simply scatters, damaging the machine gun with its remains. You can check its integrity by examining the pallet, if it is strewn with plastic fragments - it's time to change the bearing.

Volkswagen Passat B5 with automatic transmission 01M

The solenoids are quite reliable. Over time, the pressure regulator and ball-type solenoids may fail. Their normal lifespan is about ten years.

After 200,000, or better before, it is necessary to flush and clean the valve body from dirt. Dirty oil has the ability to abrasively process the insides of the valve body and "eat up" the metal of the valves and spools. The wear of the plate with dirty oil can be so severe that it must be replaced as an assembly.

Automatic transmission 01M for Volkswagen Passat B5For the Passat B6 model with automatic transmission 09G, the following repair features are characteristic: The Passat B6 automatic transmission is not demanding on completely clean oil, filters are used with an outdated design, however, they serve up to 200,000, after several oil changes and washes. However, when repairing after overheating of the box, it is better to replace the filter with a new one. When overheated, it will take away the remnants of the clutches and their glue, which will be impossible to get out of the filter. When installing such a filter back, the remnants of the clutches will fall into the box. 09G automatic transmission Volkswagen Passat B6 and SharanVolkswagen Passat B6 with automatic transmission 09GFor the Passat B6 and Sharan models with automatic transmission 5HP19 EYF, the following repair features are characteristic:

The 5HP19 EYF automatic transmission on Sharan lives well over 200,000 kilometers. This box forgives both slippage and overheating, but does not like dirty oil or its low level. Oil starvation is capable of destroying everything in the boxes. From valve body to clutches.

For the 5HP19 EYF service staff, Sharan is known primarily for its torque converters. Their forced blocking eats up the friction linings, which leads to severe oil contamination and subsequent repairs.

Automatic transmission 5HP19 EYF Volkswagen Passat B6 and SharanVolkswagen Sharan with automatic transmission 5HP19EYFRepair and diagnostic procedures for automatic transmissions require special equipment and knowledge. However, Volkswagen transmissions are well studied and if you have the means and desire, you can try to repair them yourself. But, most likely, it will be cheaper to give this business to professionals. Repair of a Volkswagen Tuareg automatic transmission in Rostov, for example, will cost from 12,000 rubles in a normal service. Trained and experienced service employees will handle the repairs much faster and better.

Symptoms: slipping began from 2nd to 3rd gear, after that the blocking of the gas turbine engine turned on - when the "R" or "D" gear was turned on, the engine practically stalled from overload, pulled out from under the brake pedal.

We remove the box itself. You can find how to do this in useful articles on our website.

We disassemble it.
The oil pump gasket is not torn.
In the reverse clutch K2 and in both brakes, the friction discs are as new:
What not to say about the K3 clutch.
These are the upper and lower metal discs: metal wear is about 0.5 mm.

Metal discs. Turned blue and cracked.

All that we managed to get out

The valve body will have to be flushed - because there are deposits from the waste metal. disks

If on your automatic transmission, switching from 2nd to 3rd gear occurs with a jerk / jerk or even a blow, think about the automatic transmission diagnosis, because if the problem is related to the box, the same will happen

This is what new steel wheels look like.

Change the piston in B1
We immerse the disks themselves in ATF.
+ New pump gasket. The rubber ring around the pump has also been replaced.
Change the piston B2

For comparison, on the right is new, on the left is old

After the planetary gearbox and one-way clutch with two retaining rings are installed, we install the sun gear drives and planetary carrier:

We fix the drive with a bolt, we hammer in the plug from the overroll whale. After that, we install the assembly K1-K3:
Then the reverse clutch K2

Then the pump. Do not forget to install the brake release springs

It remains only to twist

Our task is to rinse and clean, remove accumulated dirt.

As we can see - everything is covered in used oil and dirt

Installing the valve body in place

We wash the pallet and put a new gasket

We install the box. Fill in the oil - you're done!

HERE you can download the repair manual

To remove the gearbox, the vehicle must be raised and secured in this position. It is also necessary to use a stationary jack.

1. Remove the ground wire from the battery.

2. Remove the expansion tank of the cooling system from the bracket and, without disconnecting the hoses from it, move it to the side.

3. Loosen the clamps and remove the air tube located between the air filter and the engine.

4. Loosen the bolts securing the right front wheel, then raise the car and remove the right front wheel.

5. Remove the lower engine mudguard mounting strip.

6. Remove the upper engine cover.

7. Unscrew and remove the front exhaust pipe and catalytic converter.

8. Unscrew the bolts and remove the protective covers of the right and left drive shafts.

9. Unscrew the bolts and disconnect the inner hinges of the drive shafts from the gearbox. Using soft wire, tie the inner ends of the drive shafts to the body.

11. Unscrew the bolt (A) securing the transmission control rod and remove the rod from the transmission.Remove bolt (B) and disconnect shift rod from transmission.

12. Disconnect the tachometer (A) and reverse light (B) electrical connectors from the transmission.

13. Disconnect the ground bus from the transmission.

14. Unscrew the bolts securing the gearbox to the engine, leaving bolts A and B in place, which must be unscrewed last.

15. Install a special VAG1383A lift with bracket 3282 and an adjusting plate 3282/10 for the 012 / 01A gearbox under the gearbox. Attach the transmission to the bracket and shim plate. If no special tools are available to remove the transmission, support the transmission with a jack over a block of wood.

16. Unscrew the bolts of the right (A) and the bolt of the left (B) transmission mounts.

17. Remove the remaining two bolts (A and B) securing the transmission to the engine.

18. Move the transmission away from the engine and lower it 15 cm in order to gain access to the clutch slave cylinder.

19. Unscrew the clutch slave cylinder and, using a soft wire, tie it to the body. Do not disconnect the hydraulic hose from the clutch slave cylinder or depress the clutch pedal.

20. Using caution, lower the transmission and remove it from under the vehicle.

Device, maintenance, repair and operation of Volkswagen Passat B5 cars with gasoline engines: ADP / AHL 1.6 l 1595 cm³) 100 hp / 74 kW, ADR / AEB / APT / ARG / ANB / APU 1.8 l FSI / TFSI (1781 cm³) 125-150 HP / 92-110 kW, AGZ 2.3 l (2327 cm³) 150 HP / 110 kW, ACK / ALG / APR / AQD 2.8 l (2771 cm³) 193 HP / 142 kW and diesel AHU / AHH / AFN / AJM 1.9 l (1896 cc) 90-110-115 hp / 66-81-85 kW, AFB 2.5 l (2496 cc) 150 hp / 110 kW. Study guide, wiring diagrams, control dimensions of the body Volkswagen Passat station wagon (variant), sedan (limousine) model B5 front-wheel drive and all-wheel drive (syncro) since 1996

Video Volkswagen Passat B5 "how to replace the front wheel bearing and timing belt" (Volkswagen Passat B5)

As far as automatic transmissions are concerned, these units do not have toothed gears. In "automatic machines" the functions of these gears are performed by control units - hydraulic and electronic. Thus, during automatic gear shifting, there will be no jerks and jerks, which is due to the operation of the torque converter. It is also necessary to add that the automatic transmission uses an oil pump and an additional radiator to cool the working fluid. Unlike mechanical units, during the operation of "automatic machines" the operating temperature can be critically high. Accordingly, these units require a more improved cooling system.

When a car enthusiast drives his Volkswagen Passat b5 with automatic transmission, gears are shifted using moving clutches. In particular, the machine components (shafts and planetary elements) are decoupled and connected, which allows for acceleration and deceleration. All this happens thanks to the moving couplings.

As for the clutch itself, the principle of its operation consists in the regular compression of the annular discs by the piston, which is located in the drum. The working fluid passes through the pipes, which are located both in the drum and on the disks, as well as directly in the Passat b5 automatic transmission case, and passes to the cylinder. When there is an increase in the number of revolutions of the motor, at this moment the transmission of torque begins. In general, this is how an automatic transmission works. And the control unit manages all the processes described above.

Each unit of the car is not eternal, respectively, sooner or later the moment comes when you have to resort to repairs, including the automatic transmission. Below you can familiarize yourself with the most common breakdowns that can occur with the Volkswagen Passat b5 automatic transmission.

It is one of the most common automatic transmission malfunctions. As a rule, oil leakage occurs from under the sealing rubber of the unit. Of course, this problem must be solved by dismantling and replacing the gaskets. But it is better to prevent such an outcome, as a result of which it is necessary to periodically inspect the condition of the unit. In any case, if you notice smudges, then it will be necessary to change the transmission fluid and gaskets.

Control box malfunctions are also common failures. Most often they are found in relatively new automatic transmissions Volkswagen Passat b5. As a result of the failure of some elements of the device, the unit may incorrectly select revolutions for switching speeds, which is fraught with problems while driving. In addition, the control unit can completely block the operation of the automatic transmission, which, as you understand, will make it impossible for the car to move.The problem is solved only by full diagnostics and replacement of loops and other elements of the control unit.

Valve body malfunctions can appear in many cases, which, as a rule, are associated with incorrect operation of the unit. If the car owner does not warm up the box properly in the winter season and immediately starts driving, over time, a valve body breakdown can not just happen, it will definitely happen. If the valve body is not in order, when driving your Volkswagen Passat B5, you will feel vibrations and shocks. Sometimes the car may not go at all. If your Volkswagen Passat is relatively new, then the on-board computer will inform you about this breakdown.

Breakdowns associated with the operation of the torque converter can only be solved by repairing it. Such malfunctions are also often encountered in practice, however, their repair is cheaper than in the case of a control unit or valve body.

With a malfunctioning torque converter, you will notice:

knock of automatic transmission while driving;
rustle or rustle in the box;
very strong vibration, especially when driving at low speeds;
the vehicle loses momentum;
if you change the working fluid in the transmission, then you will see a large amount of shavings in the sump with the "working off".

It looks like an automatic transmission torque converter

If you decide to repair the Volkswagen Passat b5 automatic transmission with your own hands, then first you need to know how to remove the unit. You will find more detailed information in the photo and video, but below are general instructions for removing the automatic transmission. The processes for removing and repairing the unit with your own hands should be carried out on a lift or overpass, but in their absence, an ordinary pit will do. A transmission jack should be used to prevent further breakdowns.

Climb under the bottom of the car and perform the procedure for draining the working fluid. It is not necessary to do this, but it is advisable to facilitate the further repair procedure. When the oil is drained, it is necessary to dismantle the sump.
After that, disconnect all hoses and connections, as well as rods and connectors that may interfere with the dismantling of the unit.
Using wrenches, remove all screws that secure the torque converter. This must be done in order to dismantle the device along with the automatic transmission. Depending on the year of manufacture of the Volkswagen Passat b5, the torque converter mounts may be different, so the procedure for unscrewing the bolts may take some time. However, this process must be followed as dismantling the unit without a transformer could damage the splines on the primary pulley.
When all the torque converter screws have been removed, you need to check again if there is anything holding your transmission or not. When you are convinced that nothing interferes with the dismantling of the unit, it can be removed and pulled out. When removing the automatic transmission, hold the torque converter. This is done so that it does not accidentally jump off the pulley slot.

The procedure for troubleshooting a gearbox is to go through it completely with your own hands, which we will talk about further. Photos and videos of this process can be found below.

In general, this process of dismantling and repairing the unit requires, if not a professional, then a specialized approach. As you understand, not everyone can do such a procedure, so before you start removing and disassembling the unit, ask yourself - can you do everything correctly and efficiently? After all, an automatic transmission is not a toy, but a serious unit, without which the engine's performance will be impossible. This means that the approach to repair must be appropriate.

Video (click to play).

You can learn about the detailed procedure for repairing an automatic transmission from the video.

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