Sequence of Operations
Disassembling
Note: The differential does not need to be removed in order to remove the mentioned parts. Removal of the differential is only necessary to determine whether the allowance "r" is indicated on the ring gear. This allowance must be known if the transmission housing or tapered roller bearing for the pinion are to be replaced. An actual measurement may have to be made. refer to Removing differential and determining installation position of pinion. Service and Repair
- Clamp transmission in assembly stand.
- Drain transmission oil.
- Pull clutch release lever of ball stud and remove together with release bearing -A-.
- Unscrew guide sleeve for release bearing -B-.
- Remove Belleville spring washer -C-.
- Remove circlip -D- in front of ball bearing of input shaft and note thickness.
- Pull ball bearing out of housing.
A Puller VAG 1582 and gripper VAG 1582/2
Note: Position the puller so that the cage of the ball bearing is not damaged.
- Remove circlip (arrow) behind ball bearing; note thickness.
- Disconnect Torsen differential cover -A- from transmission cover -B- and remove along with Torsen differential.
* Remove compression spring from hollow shaft.
* Remove transmission cover -B- from transmission housing -C-.
- Remove multi-function switch (back-up light switch) (arrows).
- Remove bolts for relay shaft (arrows).
- Remove bolt for shift detent (arrow) and remove shift detent.
- Remove input shaft -A-, pinion with hollow shaft -B-, relay shaft -C-, shift rods -D- and shift forks -E- together.
Assembly
Installation is carried out in the reverse order of removal. Pay particular attention to following points:
- Assemble input shaft -A-, pinion with hollow shaft -B-, relay shaft -C-, shift rods -D- and shift forks -F- and install in housing together, in direction shown (arrow).
- Pay attention to the position of the shift linkage: refer to image shown below.
- Position of shift linkage in transmission (shown here without Input shaft and pinion)
1. 5th and reverse gear shift rod with shift fork
2. 3rd and 4th gear shift rod with shift fork
3. 1st and 2nd gear shift fork
4. Relay shaft
5. Shift detent
6. Inner shift rod
Note: Relay shaft -4- and inner shift rod -6- may also be retrofitted as follows:
- Engage 3rd gear
- Insert relay shaft -A-.
- Place inner shift rod -B- sideways onto mounting hole in transmission housing and fit together with mounting lug of relay shaft.
- Carefully swing shift rod in direction shown (arrow).
- Circlips -A- and -B- for input shaft at ball bearing must be of same thickness and be installed in original positions as prior to removal.
Note: If ball bearing, input shaft or transmission housing are replaced, re-determine correct thickness of circlips. Adjustments
- Install ball bearing for input shaft after installing cirdip -A-; push ball bearing onto input shaft as far as stop.
Installation position:
- Open side of plastic cage faces guide sleeve
- Install thrust plate -A- from tool 3235 onto ball bearing.
- Attach installing tool behind splines on input shaft and proload using two bolts -B-.
During this step, the bolts are supported in two recesses of the thrust plate.
- Press ball bearing in as far as stop by alternately tightening two bolts.
CAUTION! Tighten bolts -B- only 1/2-turn each time to prevent the ball bearing being twisted and thus damaged.
- Always install new 0-ring (arrow) on multi-function switch before installing.
- Clean sealing surfaces of transmission cover -A- and transmission housing -B-, and coal with AMV 188 200 03.
- Make sure that dowel sleeves (arrows) are installed in transmission housing -B- before installing transmission cover -A-.
- Tighten mounting bolts to 25 Nm (18 ft lb).
- Carry out the following steps before installing cover -A- with Torsen differential:
• Clean sealing surfaces and coat with AMV 188 200 03.
• Make sure dowel sleeves (arrows) are installed in transmission cover -B-.
• Install compression spring -C- over pinion onto hollow shaft.
- Tighten mounting bolts to 25 Nm (18 ft lb).