Part 1

Disassembling and assembling sequence, 02X, 6-Speed Four-Wheel Drive M/T

Removing and installing ball bearing for input shaft, end cover, Torsen differential, transmission cover, selector shaft and bearing housing with input shaft and pinion shaft/hollow shaft.





Special tools, testers and auxiliary items required
^ Drift sleeve VW 244 B
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Thrust disc VW 412
^ Tube 60 mm dia. VW 415 A
^ Thrust pad con. 8/65 VW 433

Special tools, testers and auxiliary items required





^ Sleeve VW 519
^ Holding fixture VW 540
^ Extension 30 - 23
^ Press tool 40 - 21
^ Sleeve 40 - 103
^ Thrust piece 40 - 105





Special tools, testers and auxiliary items required
^ Drift sleeve 41 - 501
^ Transmission holder 2004
^ Lock pin 2064
^ Thrust piece 3002
^ Replacement stud (M8 and M 10) 3114/2
^ Wheel bearing assembly set 3253





Special tools, testers and auxiliary items required
^ Workshop press V.A.G 1290 A
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Taper roller bearing puller V.A.G 1582
^ Adapter V.A.G 1582/12
^ - 1 - Internal puller Kukko 21/2
^ - 2 - Puller Kukko 18/2

Special tools, testers and auxiliary items required





^ - 1 - Two-arm puller Kukko 20/10
^ - 2 - Puller hook, length 200 mm
^ - 2 - Puller hook, length 250 mm
^ Fitting tool T10246
^ Holding plate T40086
^ Holding plate T40088/1
^ Sleeve T40088/2
^ Feeler gauge 2 bolts M8 (length 70 mm) with washers
^ Sealing paste AMV 188 001 02
^ Assembly sleeve 01E311120
^ Locking fluid AMV185101A1

Disassembling transmission





- Mount transmission on assembly stand.
- Place drip tray VAG 1306 under transmission.
- Drain gear oil.





- Remove clutch release lever - A - together with release bearing.
- Remove guide sleeve - B Remove dished spring - C -.
- Then remove circlip - D - in front of ball bearing for input shaft.
- If input shaft or transmission housing is not to be replaced, note thickness of circlip.





- Pull input shaft ball bearing out of transmission housing.





- Remove circlip - arrow - behind ball bearing for input shaft.
- If input shaft or transmission housing is not to be replaced, note the thickness of circlip.





- Remove bolts - arrows - and detach Torsen housing - A -.

Note:
^ The illustration shows only 4 of the 6 securing bolts.

- Remove Torsen differential and spring from pinion shaft/hollow shaft.





- Remove bolts - arrows - and remove selector shaft cover - A -.





- Remove two locking bolts - 1 - for selector shaft.

Make sure gear has not been engaged.
- Push selector shaft - 2 - into transmission as far as it will go, simultaneously removing pin - 3 -.
- Pull out selector shaft.





- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).





- Remove bolts securing transmission cover - A - and bolts securing bearing housing - B - to transmission housing - C -.
- Carefully remove transmission cover toward rear. The bearing housing remains installed to transmission housing.

Note:
^ Always replace transmission cover O-ring - arrow -.





- Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm) and washers.
- Tighten two bolts to max. 10 Nm.
- Remove oil collector - A -.





- Remove multi-point socket head bolt - 1 - for input shaft.





- Detach 6th speed selector gear with inner race for roller bearing and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10

Note:
^ Check the gear teeth on the selector gears and gear wheels for damage after pulling them off

- Remove synchro-ring and needle bearing for 6th speed selector gear.





- Pull off 6th gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm
- Remove spacer sleeve from hollow shaft.





- Remove pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -.
- Move selector fork - C - downward and detach with locking collar - D -.





- Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing hub for 5th and 6th gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm

Note:
^ Counter-hold two-arm puller using e.g. open end wrench - B -.
^ If the needle bearing inner race for 6th gear is in contact with thrust pad con. 8165 VW 433, insert lock pin 2064 into hole in input shaft to pull off the components all the way.





- Pull off 5th gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm

Note:
^ The 5th gear wheel can also be pulled off together with the 4th gear wheel.





- Pull off 4th gear wheel.

A - Puller, e.g. Kukko 18/2

Note:
^ Counter-hold puller - A - using e.g. transmission holder 2004.





- Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm
- Counter-hold two-arm puller using e.g. open end wrench - B -.
- Remove synchro-ring and needle bearing for 4th speed selector gear.





- Remove pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -
- Remove selector fork - C - with locking collar - D -.
- Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.





Remove 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.

A - Puller, e.g. Kukko 18/2

Note:
^ Counter-hold puller - A - using e.g. transmission holder 2004 to prevent plate T40086 from making contact with 3rd gear wheel or selector rod for 5th and 6th gear.

- Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.





- Pull off thrust washer - B - for 3rd speed selector gear.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm





- Remove bolts - arrows - for reverse shaft support.
- Prevent pinion shaft from falling out and secure onto hollow shaft using e.g. a hose clip A -.
- Remove two bolts - B - securing bearing housing to transmission housing and detach bearing housing.
- Remove hose clip from pinion shaft.





- Remove needle bearing - A - for pinion shaft - B - and pull out pinion shaft from hollow shaft - C -.





- Insert an internal puller - A - e.g. Kukko 21/2 into hole for reverse shaft support.
- Spread open internal puller far enough for it to make contact with reverse shaft support B -.
- Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with reverse gear wheel.





- Remove circlip for 3rd gear wheel and note thickness of circlip.





- Pull off 3rd gear wheel.

A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm
- Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.





- Remove pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.

Mark installation position of locking collar in relation to synchronizing hub - arrow -.
- Remove selector fork - C - with locking collar - D -.





- Press off synchronizing hub for reverse gear from hollow shaft.

Note:
^ Place the bearing housing onto thrust plates VW 401 and VW 402 so that the hollow shaft and selector rods are not damaged when pressing off the synchronizing hub.

- Remove reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
- Guide hollow shaft out of selector fork for 1st and 2nd gear and bearing housing.

Assembling transmission
If the input shaft or the transmission housing have been replaced, you must first redetermine the thickness of the input shaft circlips.

Note:
^ Lubricate all needle bearings with gear oil before installing.
^ Check synchro-rings for wear