Disassembly and Assembly Sequence

Disassembly and assembly sequence, 01A, 5 SPD. M/T (AWD)

Ball bearing for input shaft, multi-function sensor, input shaft, pinion shaft, shift rods, transmission cover and cover with Torsen differential, removing and installing

Special tools, testers and auxiliary items required:

^ Holding plate VW 309
^ Engine/transmission jack VW 353
^ Press device 3235
^ Socket wrench insert 3357
^ Tapered roller bearing puller V.A.G 1582
^ Attachment V.A.G. 1582/2
^ Sealant AMV 188 00102

Special tools, testers and auxiliary items required

Drip tray V.A.G 1306:

Torque wrench V.A.G. 1331:

Note:
^ To remove the above-mentioned components, it is not necessary to remove the differential.
^ Removal is only necessary when adjustments have to be performed,

Removing
^ Drain gear oil using socket wrench insert 3357.





^ Secure transmission in assembly stand.





^ Remove clutch release lever - A - with release bearing
^ Remove guide sleeve - B - Then remove curved washer - C -
^ Circlip - D - in front of ball bearing of input shaft must then be removed.
^ Note thickness of circlip, if ball bearing, input shaft or transmission housing is not replaced.





^ Pull input shaft ball bearing out of transmission housing.





^ Remove circlip - arrow - behind input shaft ball bearing.
^ Note thickness of circlip, if ball bearing, input shaft or transmission housing is not replaced.





^ Remove cover - A - with Torsen differential from transmission cover - B -.
^ Remove compression spring from pinion shaft.
^ Remove transmission cover - B - from transmission housing - C -.





^ Remove bolts - arrows - and pull out multi-function sensor.





^ Remove bolts for relay shaft - arrows -.





^ Unbolt shift detent - arrow - and swing it out.





^ Input shaft - A -, pinion shaft - B -, relay shaft - C -, shift rods - D - with shift lever and shift forks - E - must be removed carefully as a set.

Installing
If the ball bearing for input shaft, input shaft or transmission were replaced, thickness of circlips for input shaft must first be determined again.





^ Swing transmission housing into position shown.
^ After that, designated components can be inserted more easily.





^ Assemble input shaft - A -, pinion shaft - B -, relay shaft - C -, selector rods - D - with shift rod and selector forks - E -.
^ Install these components into transmission housing as a set.

Note:
^ Relay shaft - C - and shift lever can also be inserted later if necessary following illustrations N34-0585 and V34-2120.





^ Move transmission housing and engage 3rd gear in direction of - arrow -.





^ Install relay shaft - A -.
^ Place shift rod - B - sideways into mounting hole in transmission housing and assemble into mounting eye.
^ Carefully turn shift rod in direction of - arrow -.





^ Insert shift detent and tighten bolt - arrow -.





^ Screw in bolts for relay shaft - arrows -.
^ Replace O-ring for multi-function sensor.





^ Carefully insert multi-function sensor and tighten bolts - arrows -.

Check whether alignment bushings for transmission cover - A - are present in transmission housing - B - - arrows -.





^ Install transmission cover - A - on transmission housing - B -.

Check whether alignment bushings for cover - A - are present in transmission cover - B - - arrows -.

^ Insert compression spring - C -.





^ Install cover with Torsen differential - A - on transmission cover - B -.





^ Install rear circlip - arrow - for input shaft ball bearing.
^ Slide ball bearing onto input shaft.

Installation position:

Closed side of cage for balls points toward transmission housing.

^ Press in ball bearing.





Slide thrust pad - A - of press device 3235 onto input shaft.

Place press device behind clutch plate splines. Pretension bolts - B -. The bolts bear against indentations in thrust piece -A -.

Press in ball bearing onto seat by alternately tightening bolts (1/2 turn at a time) until stop is reached.





^ Install front circlip - D - for input shaft ball bearing.
^ Then install curved washer - C -.

Installation position:
Convex side faces guide sleeve - B
^ Install guide sleeve - B - for clutch release bearing
^ Install clutch release lever - A - and release bearing.