Disassembly and Assembly Sequence
Disassembling and assembling bearing plate, Torsen differential, end cover, selector mechanism (transmission side), input shaft, pinion shaft and hollow shaft
Special tools and equipment
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 412 Press tool
^ VW 415A Tube
^ VW 447 H Press plate
^ VW 454 Press piece
Special tools and equipment
^ VW 540 Engine and transmission support
^ VW 681 Oil seal extractor
^ VW 771 Multipurpose tool
^ 30-23 Extension
^ 30-100 Drift sleeve
^ 30-211A Support bridge
Special tools and equipment
^ 40-21 Press tool
^ 2064 Mandrel
^ 3116 Clamping sleeve
^ 3118 Thrust piece
^ 3121 Drift
^ 3275 Internal puller
Special tools and equipment
^ 3276 Press tool
^ VAG 1306 Drip tray or equivalent
^ VAG 1331 Torque wrench or equivalent
^ VAG 1332 Torque wrench or equivalent
^ 1 - Kukko 20/10 Two-arm puller
^ 2 - Legs Matra V/170
Disassembling
- Mount transmission on repair stand.
- Place drip tray VAG 1306 or equivalent underneath.
- Drain transmission oil (2 oil drain plugs).
- Remove bolt -1- and take off leaf spring -2-.
- Remove clutch release lever -4- with release bearing -3- and intermediate piece -5-.
- Remove guide sleeve.
- Unbolt bearing plate (arrow) and pull off.
- The coil spring -A- presses the bearing plate slightly from the end cover during pulling.
- Observe installed position of dish spring -C- when removing bearing plate.
- Installed position: outer diameter (concave side) faces shims -B-.
- Remove shims -B-, note thickness, redetermine if necessary.
- Pull Torsen differential out of end cover.
- Pull oil diverter out of end cover (arrow) far enough so that it moves freely.
- Swing oil diverter (arrow) downward and guide out through drilling in end cover.
- Remove oil diverter.
- Remove selector shaft locking bolts -A-.
- Remove 3 bolts -B- for selector shaft cover and remove cover.
- Pull out selector shaft.
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gears) by moving 2 gearshift rails (arrows).
- Loosen and unbolt multi-point socket head bolt (arrow -B-) in input shaft through hole (arrow -A-) in end cover.
- Loosen and unbolt 2 bolts (arrows -C-) for securing end cover to manual transmission and support plate (arrow -D-).
- Remove needle roller bearing support plate.
- Remove and clean 2 magnets (arrows -A-).
- Loosen and remove 5 bolts (arrows -B-) for securing end cover to manual transmission.
- Pull 2nd inside race for 4-point bearing (roller bearing side) off input shaft.
Note: The internal puller 3275 engages in a groove in the circumference of the inner race (arrow) when pulling.
- Remove end cover with end cover/gear carrier seal.
- Pull dowel sleeves out of gear carrier.
- Pull 5th gear sliding wheel with spring together with 1st inner race -A for 4-point bearing (ball bearing side) for input shaft.
B - Commercial two-arm puller, e.g. Kukko 20/10
- Remove 5th gear synchro-ring.
- Remove circlip for 5th gear wheel.
- Lock hollow shaft by engaging 2 gears.
- Pull off 5th gear wheel.
Note: Use only the hex head bolt from clamping sleeve 3116, length 50 mm.
- C - Two-arm puller, e.g. Kukko 20/10 with 200 mm legs
- Remove 5th gear shims -B-, note thickness and redetermine if necessary.
- Remove spacer sleeve -A-.
- Press out spring pin -A- for selector fork for 5th and 6th gear.
Note:
^ When pressing out synchro-ring, be careful not to damage 6th gear.
^ Do not drive out spring pin, as this will damage selector rod bearing.
- Pull selector rod on yoke together with selector fork for 5th and 6th gear and locking collar as far as possible from gear carrier (stop will be felt).
- Mark locking collar for 5th and 6th gear (arrow -1-) and synchronizing hub -A- (paired) in installed position (arrow -3-).
- Pull yoke together with selector fork and locking collar from selector rod.
- Pull 6th gear sliding wheel, 6th gear synchro-ring, 5th and 6th gear synchronizing hub and needle roller bearing inner race for 5th gear sliding wheel.
A - Commercial two-arm puller, e.g. Kukko 20/10 with 200 mm pulling legs.
- Remove selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Secure pinion shaft from sliding out of hollow shaft using clamping sleeve 3116.
- Drive dowel sleeves -A- out of bearing plate with drift 3121 and unbolt bearing plate from transmission housing.
- Separate gear carrier together with input shaft, pinion shaft and hollow shaft, and selector mechanism (transmission side) from transmission housing.
- Take circlip off 1st and 2nd gear selector rod and remove yoke -A-.
- Pull out 5th and 6th gear selector rod -B-.
- Remove reverse gear yoke -C-.
- Pull thrust washer (arrow -A-) for 6th gear needle roller bearing off shaft.
- Using pliers, take off circlip (arrow -B-) for inner race of cylindrical roller bearing.
- Remove inner race (arrow -C-) for cylindrical roller bearing (not seated tightly).
- Remove input shaft -A- with 3rd and 4th gear selector rod and selector fork from gear carrier at an angle.
- Remove hex head bolt -D-, take off spring clip -B- and retaining plate -A- and pull out reverse gear wheel axle -C-.
- Remove spring, synchro-ring and reverse gear wheel.
- Remove reverse gear relay lever.
Note:
^ If the 6th gear wheel can be easily pried off, the pinion shaft and hollow shaft may be removed together.
^ However, if the 6th gear wheel must be pressed off, remove pinion shaft from hollow shaft.
- Remove clamping sleeve 3116 for preventing pinion shaft from sliding out.
- Pull pinion shaft out of hollow shaft -D-, while catching tapered rollers -A- (23 rollers).
- Remove corrugated spring -B- and needle roller bearing -C-.
Note: Carefully protect bearing from soiling and clean if necessary.
- Examine pinion shaft/hollow shaft seating.
1. Lip ring (conical contact surface facing tapered rollers)
2. Tapered rollers (23) with wide diameter to pinion shaft head
3. Support ring (conical contact surface facing tapered rollers)
4. Corrugated spring
5. Circlip for pinion shaft tapered roller bearing
- Press off 6th gear wheel.
Note: Due to the construction of the fitting, it may happen that the wheel is easily pressed off.
- Remove hollow shaft or pinion shaft and hollow shaft with selector rod and selector fork for 1st and 2nd gear from gear carrier.
Assembling
- Insert hollow shaft with selector rod and selector fork for 1st and 2nd gear (without yoke) into gear carrier.
- Heat 6th gear wheel to about 100°C and install.
Installed position: collar facing ball bearing race
- Press on to stop so that there is no play.
- Install tapered roller bearing for pinion shaft and hollow shaft with multipurpose grease.
A - Lip ring, tapered roller (23 rollers) and support ring
B - Corrugated spring
C - Needle roller bearing
D - Hollow shaft
- Lubricate needle bearing thoroughly.
- Guide pinion shaft into hollow shaft and secure with clamping sleeve 3116 against sliding out.
- Place reverse gear relay lever-A- on relay lever bolt, paying attention to pin (limits movement of relay lever to syncro-ring).
- Insert reverse gear wheel -B- and engage relay lever in groove in reverse gear wheel.
- Insert synchro-ring -C-.
- Installed position: arrange flattened spot on circumference of synchro-ring facing input shaft (not yet installed) (arrow -1-).
- Insert spring.
- Installed position: hook end with one bend in notch in synchro-ring (arrow 2). Twist end with two bends counter-clockwise and hook in perforation in gear carrier (arrow -3-).
- Push in reverse gear wheel axle -C-.
- Set retaining plate -A- in place.
- Installed position: chamfer of drilling for synchro-ring locking pins facing gear carrier
- Insert spring clip in synchro-ring locking pins.
- Replace self-locking nut -D- and tighten to prescribed torque.
- Push input shaft -A- with 3rd and 4th gear selector rod and selector fork into gear carrier at an angle.
- Installed position of selector fork: Rib to yoke.
- Push inner race (arrow -C-) of cylindrical roller bearing onto input shaft.
- Using pliers, fit circlip (arrow -B-).
- Engage free end of relay lever (arrow -A-) in notch in reverse gear yoke.
- Push 5th and 6th gear selector rod through reverse gear yoke in direction of arrow -B-.
- Push 1st and 2nd gear yoke -A- onto selector rod and secure with circlips.
- Lubricate all input shaft and pinion shaft bearing seats in transmission housing and gear carrier as well as selector levers with gear oil.
- Carefully pry used input shaft oil seal out of transmission housing using VW 681.
- Coat sealing surfaces between gear carrier and transmission housing with sealing paste AMV 188 000 02.
- Insert complete gear carrier in transmission housing.
Note: When inserting complete gear carrier, ensure that selector rods are Rush with their bearing seats.
- Drive in two dowel sleeves for gear carrier/transmission housing.
- Tighten bolts using diagonal sequence to prescribed torque.
- Insert selector rod locking bolts with sealing paste AMV 188 001 02 and tighten to prescribed torque.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Push on thrust washer (arrow -A-) for needle roller bearing for 6th gear sliding wheel.
Installed position: collar facing circlip (arrow -B-), smooth thrust surface facing shaft end
- Lubricate needle roller bearing for 6th gear with gear oil and install.
- Push on 6th gear sliding wheel with spring and synchro-ring.
- Installed position: tabs of synchro-ring engage in notches of sliding wheel lying below
- Support input shaft with support bridge 30-211 A
- Installed position for 5th and 6th gear synchronizing hub:
- Projecting face (arrow -1-) toward end of shaft.
- Oil drilling in input shaft (arrow -2-) and oil groove of synchronizing hub (arrow -3-) align.
- Heat 5th and 6th gear synchronizing hub to about 100°C, put on shaft and drive on so that there is no play.
- Check 6th gear sliding wheel for play.
- Align marking (arrow -3-) of paired synchronizing hub -A- and 5th and 6th gear locking collar (arrow -1-).
- Put locking collar (arrow -1-) with selector fork (arrow -2-) on synchronizing hub -A- and put yoke for 5th and 6th gear -B- on selector rod -C- at same time.
Note:
^ Rib (arrow -I of selector fork must face shaft end.
^ When pushing yoke onto 5th and 6th gear selector rod, pay attention to drilling for spring pin.
- Press in spring pin -A- flush.
Note:
^ Do not drive in spring pin as this will damage selector gear bearing.
^ Fit groove in spring pin in direction of force as shown in illustration.
- Redetermine shim for 5th gear wheel:
- Put spacer sleeve -A- (length 39.6 mm) on hollow shaft.
- Put on circlip and press circlip in direction of arrow to stop.
- Determine distance between sleeve and circlip using depth gauge -B-.
Note: Determine shims according to Part Supplier.
Available shims
- Put selected shim (arrow) onto hollow shaft.
- Heat 5th gear wheel to about 100°C, put on shaft and drive to stop so that there is no play.
- Installed position: collar facing spacer sleeve.
- Redetermine circlip for 5th gear wheel:
- Determine thickest 2nd circlip which can still just be inserted and install.
Note: Determine circlips. according to parts Supplier.
Available circlips.
- Install circlip.
- Drive on inner race of needle roller bearing for 5th gear sliding wheel so that there is no axial play.
- Lubricate needle roller bearing with gear oil and fit.
- Place 5th gear synchro-ring in locking collar.
- Push on 5th gear wheel with spring.
- Heat 1st inner race for 4-point bearing (ball bearing side) for input shaft, put on input shaft and drive on to stop so that there is no play.
- Insert dowel sleeves in gear carrier.
- Install new seal for end cover.
- Set on end cover and turn in securing bolts (arrows -B-).
Note: Do not tighten bolts.
- Clean and insert 2 magnets (arrows -A-).
- Insert and hand tighten support plate.
- Installed position: tabs facing magnets.
- Tighten bolts for end plate to prescribed torque using diagonal sequence.
- Lubricate 2nd inner race for 4-point bearing (roller bearing side) and put on input shaft with ball contact surface facing 4-point bearing and drive on through drilling in end cover.
- Remove support bridge 30-211 A
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) by moving 2 gearshift rails (arrows).
- Tighten multi-point socket head bolt to prescribed torque.
- Check neutral position of yoke.
- Selector gates must align.
- Unclip oil diverter cover -3- on long end from oil diverter -1- using screwdriver and remove magnet -2-.
4. O-ring
5. Positioning segment
- Clean oil diverter.
- Assemble oil diverter.
- Push supporting arm of oil diverter from inside end cover through drilling in end cover (arrow) far enough that new O-ring can be installed to oil diverter from outside.
- Lightly lubricate new O-ring and install.
- Insert oil pipe of oil diverter into input shaft
- Turn oil diverter until positioning segment lies in recess in end cover (arrow).
- Press in oil diverter to stop.
- Push assembly sleeve -A-, Part No. 01 E 311 120, onto selector shaft -B-.
- Install complete selector shaft.
- Installed position: flattened part of selector shaft facing down
- Insert selector shaft locking bolts -A- with sealing paste AMV 188 001 02 into transmission housing and tighten to prescribed torque.
- Lubricate and insert new O-ring for selector shaft cover.
- Install selector shaft cover.
- Install bolts -B- (Qty. 3) with sealing paste AMV 188 001 02 and tighten to prescribed torque.
- Push Torsen differential onto serration of hollow shaft.
- Press Torsen differential in direction of arrow, measuring distance between upper edge of bolted end cover and front edge of outer ball bearing race of Torsen differential.
- Determine required shim(s) according to table.
Note: Determine part numbers according to parts Supplier.
The following circlips are available:
- Insert dished spring -C- in bearing plate.
- Installed position: greater diameter (concave side) facing shim
- Insert shim -B-, determined according to preceding table.
- Put spring -A- onto end of flanged shaft.
- Lightly lubricate new bearing plate O-ring and insert.
- Lubricate small needle roller bearing in pinion shaft.
- Put on complete bearing plate and evenly pull on.
- Tighten bearing plate bolts to prescribed torque using diagonal sequence.
- Tightly pull a thin insulating hose over splines of input shaft.
- Half fill new output shaft oil seal between sealing and dust lips with grease G 052 128 A1.
- Drive on input shaft oil seal.
Driving depth: 3.5 mm
Note: If the used output shaft is reused, the pressing depth is 4.5 mm.
- Remove insulating hose.
- Install clutch release bearing, clutch release lever and guide sleeve.
- Select all gears.
- Attach connecting rod.
- Check transmission gear oil.