Input Shaft/ Brg/Multi-Sw/Pinion/Shift Rods/Trans/Diff Covers

Notes:
- To remove the above-mentioned components it is not necessary to remove the differential.
- Removal is only necessary when adjustments have to be performed, Refer to list of adjustments.

Special tools and equipment
- VW309 holding plate
- VW353 transmission support
- 3235 press device
- VAG1306 drip tray
- VAG1582 taper roller bearing puller
- VAG1582/3 attachment to VAG 1582

Removing
- Place drip tray below transmission.
- Drain gear oil.
- Secure transmission to assembly stand.





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

Notes:
- Before removing the guide sleeve, slide a shrink tube over the input shaft splines to protect the seal.
- Remove the seal in the guide sleeve, Refer to Clutch, MT, Service and Repair.

- Remove guide sleeve -B-.
- Remove dished washer-C-.
- Remove circlip -D- in front of input shaft ball bearing.
- Note thickness of circlip, if ball bearing, drive axle 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, drive axle or transmission housing are not replaced.





- Remove cover -A- together with Torsen differential from transmission cover-Be.
- Remove compression spring from drive pinion.
- Remove transmission cover -B- from transmission housing -C-.





- Remove bolts (arrows) and pull out multifunction switch.





- Remove relay shaft stop bolts (arrows) items 4, 8, Refer to Input Shaft, Drive pinion, Hollow Shaft, Shift rods, transmission cover and Torsen differential cover, removing and installing.





- Unbolt shift detent (arrow) and swing it out.





- Input shaft -A-, drive pinion -B-, relay shaft -C, selector rods -D- with shift rod and selector forks -E- must all be carefully pulled out together.

Installing

Note: If the input shaft ball bearing, the input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of the circlips for the input shaft first, input shaft, adjusting, Refer to Input Shaft Adjustment.





- For easier installation of the components, swing transmission housing into position shown.





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

Note: The relay shaft -C- and the shift rod can also be installed later if necessary.





Position of shift mechanism in transmission.
1. Shift fork 5th and reverse gears
2. Shift fork 3rd and 4th gears
3. Shift fork 1st and 2nd gears
4. Relay shaft
5. Shift detent
6. Shift rod

Note: Illustration is shown without the drive axle and pinion.





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





- Install relay shaft -A-.
- Place inner 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) securely.





- Install relay shaft stop bolts (arrows).
- Replace O-ring for multi-function switch.





- Carefully insert multi-function switch and tighten (arrows).





- Make sure dowel sleeves for transmission cover-A- are installed in transmission housing -B- (arrows).
- Install transmission cover onto transmission housing.





- Make sure dowel sleeves for cover -A- are installed in transmission cover-B- (arrows).
- Install compression spring -C-.
- Install Torsen differential cover -A- onto transmission cover-Be.





- Install rear circlip (arrow) for ball bearing onto input shaft.
- Slide ball bearing onto input shaft.
- Closed side of ball cage faces toward transmission housing.





- Press in ball bearing.
- Slide thrust piece -A- of press device onto input shaft.
- Position press device behind splines for clutch plate.
- Screw in bolts -B- and tighten slightly.
- The bolts bear against the indentations in thrust piece -A-.
- Press in ball bearing onto seat by alternately tightening bolts -B- (1/2-turn at a time) until stop is reached.





- Install front circlip -D- for input shaft ball bearing.
- Install dished washer -C-.
Position: convex side faces guide sleeve -B-.

Notes:
- Before installing guide sleeve, cover splines on input shaft with a shrink-fit hose to protect the seal.
- Installing seal in guide sleeve.

- Install guide sleeve -B- for clutch release bearing.
- Install clutch release lever-A- and clutch release bearing.