DIY manual transmission repair Volkswagen Passat B5

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

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

Image - DIY manual transmission repair Volkswagen Passat B5

Attention! Car service network of favorable prices. Camber check is FREE! No queues! Repair on the same day!

Download / Print topic
Download a theme in various formats, or view a printable version of the theme.

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

Video (click to play).

Removal and installation of the gear lever knob 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 Passat B5 / B6 is distinguished by ease of management, has an affordable price. A foreign car is in demand among various categories of people. The Passat B6 model can be equipped with such well-known types of gearboxes as automatic transmission, manual transmission, manual transmission.

The automatic transmission on the Passat B5 model includes control units. Due to the operation of the transformer, jerks and jerks will not be observed when changing speed modes. This version of the checkpoint provides an automated selection of the speed mode in a specific situation. The automatic transmission is complemented by an oil pump, as well as a radiator, which is necessary to cool the flooded working fluid. The change of speeds is carried out using moving couplings. It should be noted that there are no cogwheels.

For preventive purposes, the checkpoint should be warmed up before starting to move. This procedure is especially relevant in the winter season. This has a positive effect on the valve body. If the malfunction is associated with this particular working mechanism, then vibration and shock will be felt when moving. A number of generations of VW Passat have an on-board computer, based on the readings of which it is possible to obtain information about the condition of the valve body.

Thus, the automatic transmission on the Passat model provides an effective automated selection of speed depending on the mode of movement. Timely service contributes to the extension of its resource.

When is a Volkswagen Passat automatic transmission required? Let's list the main transmission problems that the owner of this foreign car may face:

leakage of working fluid;
vibration when switching gears;
loss of performance of the control unit;
jerks from the checkpoint.

Leakage can occur from worn rubber seals. In this case, it is worth replacing these consumables with new items.

If the control unit fails on a Passat B6 or B5, an incorrect speed change is noted while driving. This mechanism is worth fully diagnosing. According to the results of diagnostics, measures should be taken to eliminate the malfunction. As a rule, replacement of loops is required.

Severe vibration can be caused by the failure of the torque converter. In parallel with this, there may be a loss of stroke dynamics.Transmission fluid should be poured into the Volkswagen car system, which will have an optimal viscosity index.It is recommended that you check the condition of the box monthly. Do-it-yourself overhaul of this unit includes the procedure for its removal. Especially for this, the car owner must carry out the following manipulations:

Place the vehicle on a jack or inspection hole.

Drain transmission fluid.

Dismantle the pallet, pipes, hoses, rods and other items related to the gearbox.

Remove the screws securing the torque converter.

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

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.

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 comes into view 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 transmission (gearbox) Volkswagen Passat B5 can be major or partial. Repair of the box (manual transmission) Volkswagen Passat B5 must be done only after initial diagnostics in a car service. Very often, a third-party opinion that the box needs to be repaired turns out to be erroneous. It can also be caused by the clutch, flywheel, and gear selector.

We offer two options for repairing a transmission (manual transmission):

Partial (local) repair of the Volkswagen Passat B5 gearbox - we remove the box, disassemble it, wash and defect. Troubleshooting a box is determining the cause of its failure, indicating a specific malfunction. A list of spare parts for this malfunction is also provided. After agreement, we make repairs to eliminate the specific malfunction that the client has contacted. We do not touch the rest of the components and spare parts in the gearbox.

Overhaul of the Volkswagen Passat B5 checkpoint - as well as with partial repairs, the box is removed and completely disassembled, washed and defective. In this case, we are not looking for a specific cause of the breakdown, but we are doing a complete defect diagnosis. All units and spare parts with increased wear, all bearings, oil seals and gaskets are determined and changed.

3 Gear lever

5 Rear body with rod B Bolt

14 Gear selector shaft

22 Shift housing

Rice. 1.1, c. Gear shift drive for gearboxes 01E

Depending on the car model, different gearboxes are installed: gearboxes 012 / 01W have 5 gears, gearboxes 01E / 0A1 have 5 or 6 gears. The gearboxes can be fitted with an aluminum or magnesium alloy crankcase. 01 E / 0A1 gearboxes are fitted to 1.9 l (85 kW) diesel engines only, and 012 / 01W gearboxes can be fitted to any engines covered in this manual. The gearbox brand is stamped on the left drive shaft flange.

The gearbox is bolted to the rear of the engine. The torque is removed from the engine crankshaft, transmitted to the clutch mechanism and then to the input shaft of the gearbox, which is seated on the splines on the clutch disc. From the gearbox, the torque is transmitted through the differential by the drive (drive) shafts to the wheels. All transmission gears have synchronizers.

The gear lever is attached to the floor of the vehicle. The rods are attached to the gear lever, through which the shifting takes place (Fig. 1.1, a. B).

switching mechanism || gear ^

01E / 0A1 brand gearboxes

1 Unscrew the handle from the gear lever, gently pry the frame and remove the gear lever cover.

2 Unscrew the retaining nuts and remove the shift housing cover.

3 Measure the distance between the back of the link and the body as shown in fig. 2.9.6. If the distance is not 49 mm, then loosen the tie rod bolt, move the rod and tighten the bolt.

4 Loosen the selector link bolt through the lever hole in the housing. Do not unscrew the bolt at all.

5 Insert a 14-inch Allen wrench between the left shoulder of the ball stop and the ramp along the ball stop as shown in fig. 2.5. Move the lever back slightly and tighten the gear selector link bolt.

6 Check the operation of the shifting mechanism. Install the shift housing cover, boot, and lever handle.

Volkswagen Passat B5 with petrol engines: ADP / AHL / ARM / ANA 1.6 l (1595 cc) 100 hp / 74 kW, ADR / AEB / APT / ARG / ANB / APU 1.8 l FSI / TFSI (1781 cc) 124 -149 hp / 92-110 kW and diesel AHU / AHH / AFN / AJM 1.9 l (1896 cm³) 90-110-115 hp / 66-81-85 kW; Operation manual, maintenance, road repair, preparation for technical inspection, color wiring diagrams, control body dimensions, device, diagnostics. Volkswagen Passat model B5 with front-wheel drive, station wagon / variant (3B5) and sedan / limousine (3B2), including special and small-scale versions from 1996 to December 2000

Video VW Passat B5 1.9 L TDI diesel how to replace the fuel filter and heater radiator / Heater core replacement (Volkswagen Passat B5 96-00)

Manual Transmission

The gearbox converts the torque transmitted from the engine in magnitude and direction. This is necessary to ensure optimal speed and cross-country ability of the car, as well as for more economical engine operation and car movement in reverse. In addition, the gearbox decouples the power unit from the transmission when the vehicle is stopped and parked and when the vehicle is coasting with the engine running.

The gearbox parts are housed in a crankcase which is bolted to the rear section of the engine.

The torque from the engine is transmitted through the clutch to the transmission input shaft of the Volkswagen Passat B5. Output Shaft The gearbox redirects torque through the differential to the drive shafts. The gear is switched on by moving the sliding sleeve of the synchronizer, as a result of which the gear is firmly in contact with the gearbox shaft.

The manual transmission gearbox is a very intricate unit and its repair must be carried out in a specialized workshop, therefore, in the current manual, only the dismantling and installation of the gearbox is presented.

Hello. Tell me please. I have a diesel Turan. 2007 year. 1'9 TDI. 105 l. With. Manual transmission. 6 steps Mileage 200 t. Km. The gearbox oil has never changed. The checkpoint works flawlessly. Whether it is worth changing the oil or not. They say it is worth changing, it will immediately make noise, howl. By the way, the official is also against the replacement. Lifetime type. How to be? Thanks and good luck.

People tell me I changed the automatic transmission to B5 1. 8. contract I did everything neatly. When I combined the box and the engine, the donut didn’t just fall out. I poured oil, started it and then refilled it using the technology. She drove and did not make any suspicious sounds. There was no puddle of oil under it. The modes were flipped. The client left and two days later I found out that the carabass had fallen apart. , plus a crash due to a broken gear plus a puddle of oil at the junction of the engine and the box. Can you screw it up?

Hello Alexander, such a question is there a 6-speed gearbox on the trade wind B5? If there is, will they fit if you put a mortar instead of 5?

good afternoon, great work, something I did not find a complete video on this box if there is a video on a longitudinally arranged box GFL Passat B5 diesel 1. 9, discard the link

Kind time of the day, tell me, 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

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

good day howls the first and second transmission? why?

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

Pros. The video is short and to the point.

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 I'm wrong?

Today, almost every motorist knows what an automatic transmission is and how it differs from "mechanics". However, not everyone knows what its principle of operation is and what to do in the event of a unit breakdown. You can find out how to find a breakdown, repair and remove an automatic transmission on a Volkswagen Passat b5 with photos and videos here.

An automatic transmission is an automatic transmission, the principle of which is to provide an automated choice of speed depending on the driving mode. And although twenty years ago automatic transmissions were not very popular among consumers, today they are even installed on Russian-made cars.

It should be noted that, in general, the scheme and principle of operation of the "automatic machine" does not differ much from mechanical units with gears of a constant type of coupling. In manual transmissions, these gears are in constant mesh when the car is moving. And when the driver shifts the gear selector, the specific gear is automatically locked on the driven shaft.

Vehicle 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, there will be no jerks and jerks during automatic gear shifting, 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.

Rate the article:

Grade 3.2 who voted: 84