Disassembling and Assembling Sequence
Disassembling and assembling sequence - 6 Spd. Manual Transmission 02X All Wheel Drive
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 M10) 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 V.A.G 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. 8/65 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 re-determine the thickness of the input shaft circlips.
Note:
^ Lubricate all needle bearings with gear oil before installing.
^ Check synchro-rings for wear
^ Insert spring in selector gear
^ Heat gear wheels, needle bearing inner races and synchronizing hubs to 130 degrees C (max.) before pressing on (wear protective gloves).
- Insert hollow shaft in bearing housing and selector fork for 1st and 2nd gear.
- Place reverse gear selector gear with needle bearing, spring and synchro-ring onto hollow shaft.
^ The tabs on synchro-ring should engage into recesses in selector gear.
- Press on reverse gear synchronizing hub.
^ Installation position: high inside collar faces 3rd gear wheel.
- Check axial clearance of reverse selector gear.
- Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an angle toward rear.
- Install reverse gear wheel and tighten 3 bolts for reverse shaft support to 30 Nm.
- Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse gear synchronizing hub.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
^ The chamfer on locking collar faces reverse selector gear.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
- Align work surface of workshop press V.A.G 1290 A so that the 3rd hole - arrow - is visible above work surface.
- Place holding plate T40088/1 with sleeve T40088/2 onto work surface.
- Insert bearing housing with shafts and selector rods into holding plate T40088/1.
The distance between input shaft - 1 - and thrust disc VW 412 should be approx. 210 mm, so that it is possible to perform the following work steps without changing the position of the work surface.
- Press on 3rd gear wheel.
^ Installation position: machined side faces reverse gear synchronizing hub.
- Insert circlip for 3rd gear wheel.
^ When replacing gear wheel or hollow shaft:
Re-determine thickness of circlip for 3rd gear wheel:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Press on thrust washer - A - for 3rd speed selector gear until limit stop.
- Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto input shaft.
- Install 3rd speed selector gear with spring and synchro-ring.
^ The tabs on synchro-ring should engage into recesses in selector gear.
- Press on heated synchronizing hub for 3rd and 4th gear
^ Installation position: high inside collar faces 3rd speed selector gear.
- Insert circlip for synchronizing hub for 3rd and 4th gear.
^ When replacing synchronizing hub or input shaft:
Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Check axial clearance of 3rd speed selector gear.
- Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and synchronizing hub for 3rd and 4th gear.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
Note:
^ Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm) into selector fork for 3rd and 4th gear.
- Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd and 4th gear - B -.
- Press on heated inner race - C - for needle bearing for 5th speed selector gear.
- Check axial clearance of 4th speed selector gear.
- Heat 4th gear wheel and press on.
^ Installation position: high inside collar faces 5th gear wheel.
- Heat 5th gear wheel and press on.
^ Installation position: high inside collar faces 4th gear wheel.
- Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.
^ The lugs on synchro-ring should engage into recesses in selector gear.
- Install and press on heated synchronizing hub for 5th and 6th gear.
- Check axial clearance of 5th speed selector gear.
- Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for 5th and 6th gear.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
- Move selector fork for 5th and 6th gear - C - into selector rod - B -.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
- Press on heated inner race for needle bearing for 5th speed selector gear.
- Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A -.
- Heat inner race - B - for needle roller bearing and press on.
- Check axial clearance of 6th speed selector gear.
- Install spacer sleeve - A - onto hollow shaft.
- Heat 6th gear wheel and press on.
Insert circlip - A - for 6th gear wheel.
^ When replacing gear wheel or hollow shaft:
Re-determine circlip - A - for 6th gear wheel:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Remove bearing housing from holding plate T40088/1.
- Push pinion shaft - B - with large needle bearing into hollow shaft - C - and fit small needle bearing - A -.
- Prevent pinion shaft from falling out and secure on hollow shaft using e.g. a hose clip.
- Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows - and washers.
- Tighten two bolts to max. 10 Nm.
Note:
^ Do not install oil collector - A - at this stage.
- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).
- Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
- Remove complete bearing housing from transmission housing.
- Check that the two dowel sleeves for centralizing bearing housing are installed in transmission housing.
- Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between transmission housing and bearing housing.
- Install bearing housing onto transmission housing.
- Clip oil collector - A - into reverse shaft support.
Note:
^ Make sure that the bolts - arrows - are removed.
- Remove hose clip from pinion shaft.
- Check that the two dowel sleeves for centralizing the transmission cover are installed in bearing housing.
- Apply sealing paste AMV 188 001 02 evenly and not too thick onto contact surfaces between bearing housing and transmission cover.
- Tighten securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C - to 35 Nm plus an additional 90 degrees 1/4 turn.
- Lubricate new O-ring - arrow - with gear oil.
- Place spring - 2 - and Torsen differential - 3 - onto pinion shaft/hollow shaft - 1 -.
- Install Torsen housing - 5 - onto transmission cover.
- Tighten bolts - 4 - to 10 Nm plus an additional 45 degrees 1/8.
- Push assembly sleeve 01E311120 - A - onto selector shaft - B -.
Note:
^ Avoid damaging oil seal - C - by only installing oil seal and selector shaft using assembly sleeve assembly sleeve 01E311120 - A -.
- Move selector rods to neutral.
- Install complete selector shaft.
^ Installation position: Chamfer of selector shaft points downward.
- Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.
^ Installation position for pin - 3 -: The groove - arrow - on pin points toward selector shaft cover.
- Clean bolt threads of locking fluid - 1 - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 45 Nm.
- Install cover - A - with new O-ring.
- Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 24 Nm.
- Install rear circlip - arrow - for input shaft ball bearing.
- Push ball bearing onto input shaft.
Installation position:
The sealed side of ball cage faces transmission housing.
- Pressing in ball bearing:
Screw replacement stud (M8 and M10) 3114/2 into tapped hole for ball head stud.
Slide thrust plate - A - of fitting tool T10246 onto input shaft.
Position fitting tool T10246 behind splines for clutch plate. Tighten bolts - B - lightly. The bolts locate in the recess in thrust plate - A -.
Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).
- Install front circlip - D - for input shaft ball bearing.
- Install dished spring - C -.
Installation position:
The curved side faces guide sleeve - B -.
- Install a shrink hose onto input shaft splines.
- Install guide sleeve - B - for release bearing.
- Remove shrink hose.
- Install clutch release lever - A - with release bearing.
- Select all gears.