Volkswagen Passat 1995 Operating instructions

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4 Spd. Automatic Transmission 096
00 - General, Technical data
Transmission identification
Code letters, model/engine applications, ratios, equipment
Capacities
Repair instructions
01 - On Board Diagnostic (OBD)
On Board Diagnostic (OBD), general information
Technical data
On Board Diagnostic (OBD) program - Guide
Electronic component locations
On Board Diagnostic (OBD) program
VAG 1551 Scan Tool (ST), connecting and selecting functions
List ofselectable functions
Diagnostic Trouble Code (DTC) Memory, checking
Diagnostic Trouble Code (DTC) table
Diagnostic Trouble Code (DTC) Memory, erasing
Basic setting, initiating
Reading measured value block
Transmission electrical testing
Electrical testing on Transmission Control Module (TCM) with 38-
pin connector
Test table
Electrical testing on Transmission Control Module (TCM) with 68-
pin connector
Test table
32 - Torque converter
Torque converter
Torque converter, identifying
Torque converter, draining
Torque converter oil seal, removing and installing
37 - Automatic Transmission - Controls, Housing
Shift mechanism, servicing
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Shift mechanism, checking
Selector lever cable, checking and adjusting
Ignition lock, checking
Shift mechanism, disassembling and assembling
Selector lever, disassembling and assembling
Locking cable, removing and installing
Locking cable, adjusting
Transmission, checking
Shift points, checking
Stall speed, checking
Main pressure, checking
Transmission, removing and installing
ATF level
ATF level, checking
ATF, topping up
Gear selector elements
Transmission, disassembling and assembling
ATF cooler and ATF filler tube, removing and installing
Planetarygearboxdisassemblyand assembly, overview
I - ATF pump to support tube, removing and installing
II - Reverse gear clutch -K2- to large sun gear, removing and
installing
III - Free wheel and reverse gear brake -B1-, removing and
installing
IV - Planet carrier and input gear, removing and installing
Planetarygearbox, disassembling and assembling
Planetarygearboxadjustments, overview
Planet carrier, adjusting
Reverse gear brake -B1-, adjusting
Clutch playbetween -K1- and -K2-, adjusting
2nd and 4th gear brake -B2-, adjusting
38 - Automatic Transmission - Gears, Hydraulic controls
ATF pump, disassembling and assembling
Free wheel with -B1- piston, disassembling and assembling
1st to 3rd gear clutch -K1- with turbine shaft, disassembling
and assembling
Reverse gear clutch -K2-, disassembling and assembling
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4th gear clutch -K3- with pump shaft, disassembling and
assembling
Valve body, removing and installing
Valve bodyconductor strip with transmission fluid temperature
sensor, removing and installing
Parking lock, disassembling and assembling
39 - Final drive, Differential
Oil in final drive, checking
Drive flange oil seal, removing and installing
Final drive, disassembling and assembling
Repair overview
Input gear, removing and installing
Drive pinion, removing and installing
Differential, removing and installing
Differential, disassembling and assembling
Final drive, adjusting
Adjustment overview
Adjustments to be completed after replacing individual components
Drive pinion, adjusting
Input gear, adjusting
Differential, adjusting
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00-1
Transmission identification
The 4-speed automatic transmission 096 is
installed in the Passat beginning in the 1995
model year.
It may be installed in combination with either a 4-
cylinder or a 6-cylinder engine. Applications
page 00-3 .
The transmission is identified by type (096), code
letters and date of manufacture.
Location on transmission
Code letters (arrow -1-)
Automatic transmission 096 (-arrow 2-)
Automatic transmission 096 (-2-)
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Transmission identification
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00-2
Transmission code letters anddate of
manufacture (arrow -1-)
The code letters of the transmission are also listed on
the vehicle data plates.
Example: CFF 03 01 4
II I I
II I I
Transmission
code letters Day Month Year
Date (e.g. 3 Jan.,1994)
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Transmission identification
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00-3
Code letters, model/engine applications, ratios, equipment
Automatic transmission 096
Transmission Code letters CFF CNK
Manufactured from:
to: 01.93
08.93
Torque converter Code letters QCCR QACA
Valve body Code letters QBA QBA
Manufactured from:
to: 10.93
10.93
Number of plates Inner Outer Inner Outer Inner Outer
Clutch -K1- 5555
Clutch -K2- 5555
Clutch -K3- 6554
Brake -B1- 5555
Brake -B2- 6767
Application Model Passat 1995 Passat 1995
Engine 2.8 liter - 128 kW
(172 hp)
2.0 ltr. - 85 kW
(115 hp)
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Code letters, model/engine applications, ratios, equipment
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00-4
Transmission Code letters CFF CNK
Ratios 1st gear 2.714 :1 2.714 :1
2nd gear 1.441 :1 1.441 :1
3rd gear 1.000 :1 1.000 :1
4th gear 0.743 :1 0.743 :1
Reverse gear 2.884 :1 2.884 :1
Intermediate drive No. of teeth Input gear 62 62
Output gear 61 61
Ratio 0.984 0.984
Final drive No. of teeth Drive pinion 20 18
Final drive gear 74 76
Ratio 3.700 :1 4.222 :1
Drive shaft Flange diameter - mm 100 star-shape
ATF cooler Equipment Pressure-side 6-row Pressure-side 6-row
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Code letters, model/engine applications, ratios, equipment
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00-5
Capacities
Planetary gearbox
Capacities Planetary
gearbox Automatic transmission
Initial filling 5.6 liters
(5.9 US qt.)
096
Oil change approx. 3.0
liters
(3.2 US qt.)
Lubricant ATF Dexron
Final drive
Capacities Final drive Automatic
transmission
Initial filling 0.75 liter
(0.79 US
qt.)
096
Oil change Filled for life
No change
Lubricant Gear oil
SAE75
W90
(synthetic
oil)
Note:
Gear oil SAE 75 W90 (synthetic oil) is available
as follows:
0.5 liter container - Part No. G 052 145 A1
1.0 liter container - Part No. G 052 145 A2
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Capacities
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00-6
Repair instructions
The maximum possible care and cleanliness and
proper tools are essential to ensure satisfactory
and successful transmission repairs. The usual
basic safety precautions also naturally apply
when carrying out vehicle repairs.
A number of generally applicable instructions for
individual repair operations, which are otherwise
mentioned at various points in the Repair
Manual, are summarized here. They apply to this
Repair Manual.
Transmission
When an automatic transmission is replaced, the
ATF in the planetary transmission ( page 37-
43 ) and the gear oil in the final drive ( page
39-1 ) is to be checked and topped up as
necessary. ATF and oil capacities and
specifications page 00-5 .
When installing the transmission, make sure
that the dowel sleeves for engine/transmission
alignment are installed correctly.
Gaskets, oil seals
Always install new O-rings.
Radial shaft seals: Pack space between sealing
lips (arrow) with grease before installing.
After installing, check gear oil level or ATF level
and adjust to correct level if necessary.
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Repair instructions
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00-7
Locking elements
Do not overstretch circlips; replace if
necessary.
Circlips must be properly seated in the
grooves.
Nuts, bolts
Nuts and bolts for attaching covers and
housings must be loosened and tightened
evenly, in an alternating pattern.
Do not distort particularly sensitive parts, e.g.
valve body, and loosen or tighten diagonally in
stages.
Tightening torques listed apply to unoiled nuts
and bolts.
Threads of bolts that are secured by locking
fluid are to be cleaned with a wire brush. Then
insert bolts with AMV 185 100 A1.
Always replace self-locking nuts.
Bearings
Install needle bearings with the inscribed side
(thicker sheet metal) facing the drift.
Lubricate all bearings in transmission with gear
oil before installing. Oil with special care for
measuring friction torque.
Heat the inner races of tapered roller bearings
to approx. 100C (212F) before installing.
Do not interchange the inner or outer races
between bearings of the same size.
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Repair instructions
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When tapered roller bearings are mounted on a
shaft, always replace them together and use
bearings from the same manufacturer.
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Repair instructions
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00-8
Shims
Measure shims at several points with a
micrometer. Different tolerancesin shims of the
same nominal size make it possible to obtain
the exact shim thickness required.
Check for signs of burrs and damage. Only
install shims that are in perfect condition.
Inner plates
Place new inner plates in ATF fluid for 15
minutes before installing.
Valve body
Replace the valve body if any of the selector
elements is scorched.
Clutches
Clutches K1, K2 and K3 should initially be
dismantled only for cleaning. If parts are
malfunctioning, replace clutch.
Clutch applications are determined by the
transmission code letters.
On Board Diagnostic (OBD) program
Before carrying out any automatic transmission
repairs, first determine the cause of the
malfunctionas precisely as possible with the
aid of the On Board Diagnostic capability of the
Transmission Control Module Repair Group
01.
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01-1
On Board Diagnostic (OBD),
general information
Function
The 096 automatic transmission is controlled
electro-hydraulically. "On Board Diagnostic"
capability refers specifically to the electrical and
electronic controls.
The Transmission Control Module (TCM) -J217-
receives input signals from components that
effect gear selection, and sends output signals to
solenoid valves that control gear selection in the
valve body.
The TCM -J217- is equipped with Diagnostic
Trouble Code (DTC) Memory so that, in the
event of an electrical/electronic component
malfunction or an open circuit, the cause of the
malfunction can be determined quickly.
Malfunctions in the monitored sensors or
components are stored in DTC Memoryalong
with an indication of the type of malfunction
Malfunctions that occur only occasionally are
defined as "sporadic" malfunctions and are
coded as such.
The Transmission Control Module (TCM) -J217-
analyzes the information and distinguishes
different types of malfunctions. Those that do not
reoccur within 5 to 20 km (3 to 12 miles) or 6 to
24 minutes are stored as sporadic malfunctions.
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On Board Diagnostic (OBD), general information
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01-2
Electrical malfunctions that affect vehicle
performance can be identified using the VAG
1551 Scan Tool (ST). The On Board Diagnostic
(OBD) capabilities can only be fully exploited
using operating mode 1 ("Rapid data transfer").
Functions of the VAG 1551 Scan Tool (ST)
List of selectable functions, page 01-24 .
Safety functions of the Transmission Control
Module (TCM)
If critical malfunctions occur while driving, the
transmission will continue to operate in an
emergency running mode. If a malfunction
occurs while the selector lever is in position "D,"
"3" or "2," the 3rd gear emergency running mode
is activated.
If a malfunction occurs while the selector lever is
in position "1," "P," "N" or "R" the emergency
running mode for that stage is activated.
If the engine is started again in the emergency
running mode and the malfunction occurs when
the selector lever is in position "D", "3" or "2" then
3rd gear is activated hydraulically, until the
malfunction is repaired.
If there are malfunctions that result in emergency
running, the transmission remains in the
emergency running mode until the ignition is
switched off.
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On Board Diagnostic (OBD), general information
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01-3
Malfunctions that may activate emergency
running mode:
Open circuit in wiring, short-circuit, malfunctions
in electrical or hydraulic components.
Transmission Control Module (TCM)
recognition of malfunctions
If a malfunction exists for a certain time, it is
stored as a static malfunction. A malfunction that
is recognized but does not occur again within a
certain time or distance is stored as a "sporadic
malfunction."
Malfunctions that are stored in DTC Memory as
sporadic malfunctions will be displayed as such
when retrieved by the VAG 1551 Scan Tool (ST).
In such cases, the letters "SP" appear on the
right side of the Scan Tool display. If the printer
is switched on, "sporadic DTC" is printed out
after the malfunction is addressed.
Malfunctions that are stored in DTC Memory as
sporadic malfunctions are automatically erased
after 1,000 km (600 miles) or 20 hours.
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On Board Diagnostic (OBD), general information
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01-4
Technical data
Memory
Permanent memory
Volatile memory
yes
no
Data output
Rapid data transfer
Blink-code output
yes
no
Output Diagnostic
Test Mode (DTM) no
Basic setting yes
Transmission Control Module
(TCM) coding no
Reading measured value block
((VAG 1551 function 08) yes
Component locations page
01-7
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On Board Diagnostic (OBD), general information
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01-5
On Board Diagnostic(OBD) program - Guide
Troubleshooting Automatic Transmission with VAG 1551 ScanTool (ST)
Connect VAG 1551 Scan Tool (ST) and select
1- Rapid data transfer
Enter address word 02 Transmission electronics
Check control module identification
Check DTC Memory (function 02) No DTC recognized
Identification NOT OK
Correct malfunction according to DTC table End
Replace control
module Read measured value block - 08
Replace component Transmission: Perform electrical
tests
Results as specified Results not as specified
A B C D
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01-6
AB C D
Check wiring according to wiring diagrams
Electrical Wiring Diagrams, Troubleshooting
and Component
Locations binder
Check DTC Memory (function
02)
and
Erase DTC Memory (function
05)
Replace component
Initiate basic setting (function
04)
Carry out road test
and
Check DTC Memory again (function 02)
If No DTC recognized! is indicated on display
the On Board Diagnostic program has been
completed
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