01E Manual Transmission

Transmission layout





1. Engine
2. Clutch
3. Transmission
4. Input shaft
5. Front differential
6. Front pinion shaft (output shaft)
7. Hollow shaft
8. Torsen differential
9. Driveshaft
10. Rear drive pinion
11. Rear differential
Arrows point in direction of travel





Gear ratios

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A1 - Final drive, front
A2 - Final drive, rear
T - Speedometer drive
Arrows point in direction of travel
Transmission
^ When installing ensure that the dowel sleeves between the engine and transmission are correctly located.
^ When changing a transmission, check the oil level and top up if necessary.
^ When changing a rear final drive fill with gear oil up to lower edge of filler hole.
^ Capacities and specifications for manual transmission; Refer to Specifications; Capacities

Gaskets, sealing rings
For sealing surfaces with paper gaskets:
^ Replace paper gaskets.
For sealing surfaces with sealant:
^ Thoroughly clean joint surfaces and apply sealant AMV188001 02.
^ Apply sealant uniformly but not too thick.
^ Replace"O-rings".
^ Radial shaft oil seals.





Before installing
^ Lightly oil outer edge and half-fill space between sealing lips (arrow) with grease G 052 128 A1.

After installation
^ Check transmission gear oil level.
^ Check final drive oil level; top-up to lower edge of oil filler hole if necessary.

Locking devices
^ Replace circlips.
^ Do not overstretch circlips.
^ Circlips must locate properly in the groove.





^ Replace spring pins. Installation position: Slot longitudinal to line of force.
^ Always replace roll pins.

Bolts and nuts
^ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
^ Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
^ Tightening torques as specified are for unoiled bolts and nuts.
^ Replace self-locking bolts and nuts.
^ Use a thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a risk that the bolts will shear the next time they are removed.

Bearings
^ Install needle bearings with lettered side (thicker metal) towards installation tool.
^ Tapered roller bearings installed on one shaft must be replaced as a set. Use same make of bearings if possible!
^ Install new roller bearings as delivered and do not apply additional lubrication.
^ Heat inner races to approximately 100°C before installing.
^ Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.
^ Grease the transmission input shaft needle bearing in the flywheel.

Shims
^ Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
^ Check for burrs and damage.
^ Only install perfect shims.

Synchronizer rings
^ Do not interchange. When reusing always install on the same gear.
^ Check for wear and replace if necessary.
^ Coat with gear oil before installing.

Gear wheels, synchro-hub
^ Before installing clean and heat on a hot plate to approximately 100°C.
^ Temperature can be checked with temperature tester VAG 1558, ignition tester VAG 1767 or Diesel tester VAG 1743.

Selector gear wheels
^ After assembly, check sliding gear wheels of 1st through 6th gear for axial play of 0.15...0.35 mm or freedom of movement.