Ball Bearing For Input Shaft, Multi-Function Sensor, Input Shaft, Drive Pinion, Selector Rods and Transmission Cover, Removing

Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion, selector rods and transmission cover, removing and installing





Special tools and workshop equipment required
^ VW 309 Holding plate
^ VW 353 Transmission support
^ 3235 Press Device
^ 3357 Triple square socket driver
^ VAG 1582 Tapered roller bearing puller
^ VAG 1582/2 Gripping piece

Special tools and workshop equipment required





^ VAG 1306 Drip tray





^ VAG 1331 Torque wrench
^ Sealant AMV 188 001 02

Notes:
^ It is not necessary to remove the differential to remove the above-mentioned components.
^ Removal is only necessary when adjustments have to be carried out adjustment overview.

Removing
- Place drip tray VAG 1306 underneath the transmission.
- Drain gear oil, using socket attachment 3357.





- Secure transmission to repair stand.





- Detach clutch release lever -A- with release bearing.

Note: Cover input shaft splines with a shrink-fit hose to protect oil seal, before puffing off guide sleeve.
- Remove guide sleeve -B-.
- Remove dished washer -C-.
- In front of input shaft ball bearing remove circlip -D-.
- Note the thickness of the circlip, if the ball bearing, input shaft or transmission housing is not being replaced.





- Pull the input shaft ball bearing out of the transmission housing.





- Remove the circlip (arrow) behind the input shaft ball bearing.
- Note the thickness of the circlip, if the ball bearing, input shaft or transmission housing is not being replaced.





- Remove transmission cover -A- from transmission housing -B-.





- Remove bolts (arrows) and pull out the multi-function sensor.





- Remove relay shaft bolts (arrows).





- Remove detent segment (arrow) and swivel it out.





- The input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector forks -E- must be carefully pulled out together.

Installing

Note: If input shaft ball bearing, input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of circlips for input shaft adjusting input shaft.





- For easier installation of following components, swing transmission housing into the position shown.





- Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector forks -E-.
^ Install these components together into transmission housing.

Note: Relay shaft -C- and selector shaft can also be installed later.





Location of shift mechanism in transmission
1 - Selector fork for 5th gear and reverse gear
2 - Selector fork for 3rd gear and 4th gear
3 - Selector fork for 1st gear and 2nd gear
4 - Relay shaft
5 - Detent mechanism
6 - Selector shaft

Note: Shown in illustration with input shaft and drive pinion removed.





- Turn transmission housing and engage 3rd gear (direction of arrow).





- Install relay shaft -A-.
- Insert selector shaft -B- sideways into hole in transmission housing and assemble into mounting eye.
- Turn the selector shaft in direction of arrow.





- Insert the detent segment and tighten bolt (arrow).





- Install relay shaft bolts (arrow).
- Replace O-ring for multi-function sensor.





- Carefully insert multi-function sensor and tighten (arrow).





Check that dowel sleeves for transmission cover -A- are installed in transmission housing -B-.
- Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.
- Install transmission cover onto transmission housing.





- Install rear input shaft ball bearing circlip (arrow).
- Slide the ball bearing onto input shaft.
^ Installation position: Closed side of ball cage faces toward transmission housing





- Press in ball bearing:
- Slide thrust pad -A- on press-in tool onto input shaft.
- Position press-in tool behind splines for clutch plate.
- Install bolts -B- until they make contact.
^ The bolts bear against the indentations in thrust pad -A-.
- Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).





- Install front circlip -D- for the input shaft ball bearing.
- Install dished washer -C,
^ Installation position: Convex side toward guide sleeve -B-

Note: Before installing guide sleeve, cover input shaft splines with a shrink-fit hose to protect oil seal.





- Install guide sleeve -B- for release bearing.
- Install clutch release lever -A- and release bearing.