Input Shaft, Pinion Shaft, Selector Rods and Transmission Cover

Input shaft, pinion shaft, selector rods and transmission cover, disassembling and assembling





1. Selector rod with selector fork for 3rd and 4th gear
- Disassembling and assembling
- Replacing mounting bushes
2. Input shaft
- Disassembling and assembling
- Adjusting
- Servicing input shaft bearings
3. Left stop screw, 40 Nm
4. Shim
5. Relay shaft
- Installation position
6. Shim
7. Right stop screw, 40 Nm
- The stop screws (items 3 and 7) are made from different materials for aluminum and magnesium transmissions
- Allocation
See Parts Supplier
8. Selector shaft
- Installation position
- Replacing selector shaft oil seal
9. Detent segment
- Installation position
10. Torx screw, 25 Nm
- With shoulder to secure the detent element spring
11. Selector rod with 1st 2nd/5th and reverse selector forks
- Disassembling and assembling
- Replacing mounting bushes
12. Pinion shaft
- Disassembling and assembling
- Adjusting
- Servicing pinion shaft bearings
13. Transmission cover
- If aluminum (bright), can only be fitted to en aluminum transmission housing
- If magnesium (matt grey), can only be fitted to a magnesium transmission housing
- Removing and installing oil collector tray see Fig. 1
14. Transmission housing
- If aluminum (bright), can only be fitted to en aluminum transmission cover
- If magnesium (matt gray), can only be fitted to a magnesium transmission cover
- Transmission cover and transmission housing identification shortly after start of production see Fig. 2
- Allocate components according to transmission code letters using parts catalog
15. Torx screw
- For aluminum transmissions 43 mm long
- 25 Nm
- For magnesium transmissions 48 mm long
- From transmission build date 25.09.7 modified for magnesium transmissions see Fig. 3
- Always replace
- 20 Nm





Fig. 1 Removing and installing oil collector tray

Removing
- Turn the oil collector tray and then pull out

Installing
Installation position:
The oil collector tray faces upwards in transmission cover.
- Push oil collector tray into the transmission, until it snaps in.





Fig. 2 Transmission cover and transmission housing markings
The inscription Mg Al 9 Zn 1 can be found in vicinity of arrows 1 and 2 on transmissions manufactured from magnesium
Mg = Magnesium; additional data is only for production.





Fig. 3 Transmission cover securing bolts to transmission housing modified for magnesium transmissions
From transmission build date 25.09.7 only bolts with a washer are installed in the 5 lower holes (arrows).
The bolts have a length of 51 mm
- In this area no bolts without washers must be installed.
Otherwise the transmission cover below the bolt head contact surface will be damaged due to contact corrosion.

Assembly sequence
Disassembling and assembling input shaft ball bearing, multi-function sender, input shaft, pinion shaft, selector rods and transmission cover.

Special tools and workshop equipment required





- VW 309 Holding plate
- VW 353 Transmission support
- 3235 Press
- 3357 Torx socket
- VAG 1582 Taper roller bearing puller
- VAG 1582/2 Adapter





- VAG 1306 Drip tray





- VAG 1331 Torque wrench

Notes:
- To remove the above-mentioned components it is not necessary to remove the differential.
- Removal is only necessary when adjustment work must be carried out.

Disassembling
- Place drip tray VAG 1306 under transmission.
- Drain transmission oil with key 3357.





- Mount transmission on repair stand.





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

Note: Before removing guide sleeve, pull shrink tube over input shaft splines to protect oil seal.

- Remove guide sleeve -B
- Remove dished washer -C-
- Remove circlip -D- in front of bail bearing.
- If the ball bearing, input shaft or transmission housing is not to be replaced, note the thickness of the circlip.





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





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





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





- Remove bolts (arrows) and pull out the multifunction sender.





- Remove relay shaft bolts (arrows)





- Then unbolt the detent segment (arrow) and swing it out.





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

Assembling
When the input shaft ball bearing, the input shaft or the transmission housing is replaced, first of all the thickness of the circlip for the input shaft must be redetermined.





- Swing the transmission housing into the position shown.
- It is then easier to install the following mentioned components.





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

Note: If necessary the relay shaft -C- and the selector shaft can be subsequently installed.





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





- Now install relay shaft -A-.
- Insert selector shaft -B- sideways onto the drilling in transmission housing and assemble into mounting eye.
- Then turn the selector shaft carefully in direction of arrow.





- Then insert the detent segment and bolt it tight (arrow).





- Then insert detent element and bolt it tight (arrow).
- Replace O-ring for multi-function sender.





- Carefully insert multi-function sender and tighten (arrows).
Check whether the dowel sleeves for the transmission cover -A- are fitted in transmission housing -B-.





- Fit transmission cover -A- onto transmission housing -B-.





- Fit rear input shaft ball bearing circlip (arrow).
- Then slide the ball bearing onto the input shaft.
Installation position: The closed side of the ball cage faces to transmission housing.





- Press in ball bearing:
Slide the pressure plate -A- of the fitting tool onto the input shaft.
Place fitting tool behind the clutch plate splines. Pretension bolts-Be. The bolts locate in the recess in the pressure plate -A-.
Press ball bearing in onto stop by alternately tightening the bolts (1/2 turn).





- Now fit the input shaft ball race front circlip -D
- Then fit dished washer -C-.
Installation position: The convex side faces to guide sleeve -B-.

Note: Before removing guide sleeve, pull shrink tube over input shaft splines to protect oil seal.

- Fit release bearing guide sleeve -B-.
- Fit clutch release lever -A- and release bearing.