Jetta's® Going Nowhere - I Want to Go Skiing

"Hey, let's go skiing tomorrow," yelled Cameron, one of my fellow technicians from across the shop. "I'd like to," I replied. "But I promised the customer I would figure out why his Jetta's automatic transmission is toast before Monday." (We'll work sometimes on Saturday just to catch up on jobs.) It was already Friday morning, and I wasn't too optimistic. Cameron leaned on the fender of the Jetta and asked, "Have you checked the ALLDATA® yet?"

"Actually, the customer brought in a technical service bulletin (TSB) title that he got from the 'Vehicle Owner' section of ALLDATA.com," I said. "All I have to do is look up the TSB by the title or number and get the details. Hopefully it won't be something serious; I'd like to go skiing, and I'd really like to see how my new four wheeler handles in the snow."

After quickly making a few routine checks, I looked up the TSB title that the customer had provided. The TSB offered a simple explanation for the problem and an even easier repair. I was elated. Listed below is what was required for the repair:

Some 1996 Volkswagen® Jetta®, Golf® and Passat® models, equipped with an 01M Transmission and built between August 1, 1995 and December 19, 1995 (see transmission identification example), may exhibit problems to include: no second gear, no fourth gear, or will not move forward in any gear. The cause of the problems may be due to broken retaining lugs for the selector plugs, which causes the selector valves to partially protrude or completely fall out of the valve body.

To repair this problem, you must first drain the fluid, remove the transmission oil pan and remove the filter screen. The remainder of the repair procedure is as follows:

1. Remove the valve body plug (arrow 1) for the limit selector by turning it counterclockwise, and install the white plug from the repair kit.

2. Remove the valve body plug (arrow 2) for the manual 1 selector by turning it counterclockwise, and install the white plug from the repair kit.

NOTE: Replacing the plugs one at a time will ensure that springs behind the plugs are not mixed up. Springs behind the plugs are NOT interchangeable and must always be installed in the same location. Plugs are correctly installed when the outer plastic lugs are in the vertical position.

3. Remove the valve body plug for the B2 selector (arrow 3) by turning it counterclockwise and install the white plug from the repair kit.

4. Remove the valve body plug for the K1 selector (arrow 4) by turning it counterclockwise and install the white plug from the repair kit.

5. Install the new screen gasket into the valve body.

6. Firmly press the screen onto the valve body.

7. Reinstall the oil pan.

NOTE: Always replace the screen and pan gaskets, and always press the spacer bushing into the new pan gasket and torque pan bolts to 9 ft lbs (12 Nm).

8. Fill and check the transmission fluid level.

9. Test-drive the vehicle to verify that the repairs have been completed properly to ensure customer satisfaction.

When I checked the selector valves, two of them were already hanging half way out of the valve body. After installing the repair kit (Volkswagen part # 01M 398 998), I refilled the transmission with fresh fluid and went for a test drive. Cameron took the Jetta for the important "quality control" test drive. We both agreed that the transmission operated perfectly.

The customer was happy to get his car repaired by Friday afternoon and was really jazzed about assisting us with the TSB title. I was glad we had ALLDATA to give us the current TSB information and excited to have the free time to go skiing on Saturday. By the way, the new four-wheel drive works great in the snow.