Input Shaft/Bearing, Drive Pinion, Selector Rods
Notes:^ To remove the above-mentioned components it is not necessary to remove the differential.
^ Removal is only necessary when adjustments have to be carried out, Refer to Adjustment Overview.
Special tools, testers and auxiliary items
^ Socket 3357
^ Retaining plate VW 309
^ Transmission support VW 353
^ Removal tool V. A. G. 1582
^ Clamping piece V. A. G. 1582/2
^ Pressing-in tool 3235
^ Collector tray VAG1306
^ 188 200 03 or AMV 188 001 02
Removing
- Place a drip tray underneath.
- Drain gear oil.
- Secure transmission in assembly stand VW 540.
- Remove clutch release lever -A- with release bearing.
Notes:
^ Before pulling off guide sleeve, cover splines on input shaft with a shrink-fit hose to protect oil seal.
^ Removing oil seal in guide sleeve.
- Remove guide sleeve -B-.
- Remove dished washer -C-.
- Remove circlip -D- in front of input shaft ball bearing.
- If the ball bearing, input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
- Pull the input shaft ball bearing out of transmission housing.
- Remove the circlip (arrow) behind the input shaft ball bearing.
- If the ball bearing, input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
- Unbolt cover -A- with Torsen differential from transmission cover -B-.
- Remove spring from drive pinion.
- Then unbolt transmission cover -B- from transmission housing -C-.
- Remove bolts (arrows) and pull out the multifunction sender.
- Remove relay shaft bolts (arrows).
- Unbolt the detent segment (arrow) and swing it out.
- The input shaft -A-, the drive pinion -B-, the relay shaft -C-, the selector rods -D- with selector shaft and the selector forks -E- must be carefully pulled out together.
Installing
Note: If the input shaft the input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of the circlips for the input shaft.
- Swing the transmission housing into the position shown.
- It is then easier to install the following mentioned components.
- Assemble the input shaft -A-, the drive pinion -B-, the relay shaft -C-, the selector rods -D- with selector shaft and selector forks -E- together.
- Install these components together into the transmission housing.
Note: The relay shaft -C- and the selector shaft can also be installed later if necessary.
- Turn transmission housing and engage 3rd gear (direction of arrow).
- Now install relay shaft -A-.
- Insert selector shaft -B- sideways onto the drilling in transmission housing and assemble into mounting eye.
- Then turn the selector shaft carefully in direction of arrow.
- Then insert the detent segment and bolt it tight (arrow).
- Now insert the relay shaft bolts (arrows).
- Replace O-ring for multi-function sender.
- Carefully insert multi-function sender and tighten (arrows).
- Check that dowel sleeves for transmission cover -A- are fitted in transmission housing -B- (arrows).
- Lightly coat sealing surfaces with AMV 188 001 02.
- Fit transmission cover onto transmission housing.
- Check that dowel sleeves for cover -A- are fitted in transmission cover -B- (arrows).
- Fit spring -C-.
- Fit cover with Torsen differential -A- on transmission cover -B-.
- Fit rear input shaft ball bearing circlip (arrow).
- Slide the ball bearing onto the input shaft.
Position: closed side of ball cage faces toward transmission housing
- Press in ball bearing.
- Slide thrust piece -A- of pressing-in tool onto input shaft.
- Position pressing-in tool behind splines for clutch plate.
- Screw in bolts -B- until they make contact.
The bolts bear against the indentations in thrust piece -A-.
- Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).
- Now fit the input shaft ball race front circlip -D-.
- Then fit dished washer -C-.
Position: convex side toward guide sleeve -B-.
Notes:
^ Before fitting guide sleeve, cover splines on input shaft with a shrink-fit hose to protect oil seal.
^ Installing oil seal in guide sleeve.
- Fit guide sleeve -B- for release bearing.
- Fit clutch release lever-A- and release bearing.