Installing
Installing
- Fit hollow shaft with selector fork and selector rod for 1st and 2nd gear (without follower) into bearing plate.
- Heat 6th gear to approximately 120°C and fit on.
Installation position: shoulder towards tapered roller bearing
- Press onto stop; ensure there is no play.
- Grease drive pinion/hollow shaft tapered roller bearing with multi-purpose grease before inserting.
Allocation, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (Assembly Sequence)
A- Flange ring, tapered rollers (Qty. 23), and support ring
B - Corrugated spring
C- Needle ring
D - Hollow shaft
- Oil needle bearing well.
- Insert drive pinion into hollow shaft and secure with hose clip to prevent it slipping out.
- Fit relay lever -A- for reverse gear onto bolt for relay lever. Watch position of pin when doing this (limits relay lever travel to synchro-ring).
- Insert sliding gear-B- and engage relay lever with groove on sliding gear.
- Insert synchro-ring -C-.
Installation position: position flat on circumference of synchro-ring towards input shaft (not as yet fitted) (arrow -1-)
- Insert spring.
Installation position: hook single angled end into recess on synchroring (arrow -2-). Turn double angled end anti-clockwise and hook into opening in bearing plate (arrow-3-)
- Insert shaft -C-.
- Fit retaining plate -A-.
^ Installation position: chamfers of holes for locking pins of the synchro-ring face bearing plate
- Insert spring clasp -B- into locking pins of the synchro-ring.
- Replace self-locking nut-D- and tighten to 25 Nm.
- Slide input shaft -A- with selector rod and selector fork for 3rd and 4th gear at an angle into bearing plate.
^ Selector fork installation position: rib towards follower, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (Assembly Sequence)
- Slide inner race (arrow -C-) for cylinder roller bearing onto main shaft at flange for end cover (clearance fit).
- Fit circlip (arrow -B-) using right angled circlip pliers.
- Engage recess in follower for reverse gear with the free end of relay lever (arrow -A-).
- Slide selector rod for 5th and 6th through follower for reverse gear in direction of (arrow-B-).
- Slide follower -A- for 1st and 2nd gear onto selector rod and secure with circlips.
- Oil all bearings of input shaft and drive pinion/hollow shaft in transmission housing and bearing flange as well as selector rods with gear oil.
- Pry used seal for input shaft carefully out of transmission housing with VW 681.
- Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 000 02 or AMV 188 001 02 sealing paste.
- Insert complete bearing plate into transmission housing.
Note: When inserting the complete bearing plate, ensure that the selector rods align with their mounting points.
- Drive in 2 dowel sleeves for bearing flange/transmission housing.
- Tighten 12 bolts using diagonal sequence to 25 Nm.
- Screw in locking bolts for selector rods.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
Note:
^ Aluminum and steel bolts must not be interchanged when installing.
^ Tightening torques: for aluminum locking bolts = 50 Nm, and for steel locking bolts = 70 Nm
- Fit thrust washer (arrow -A-) for needle bearing for 6th speed gear.
Installation position: shoulder towards circlip (arrow -B-), smooth contact surface to shaft end
- Oil needle bearing for6th speed sliding gear with gear oil and fit.
- Slide on 6th speed sliding gear with spring and synchro-ring.
Synchro-ring installation position: the lugs of the synchro-ring engage into the recesses below in the sliding gear
- Support input shaft with support bridge 30-211 A.
Installation position of synchro-hub for 5th and 6th gear:
- Side with projecting face (arrow -1-) faces shaft end
- The oil drilling of the input shaft (arrow -2-) and the oil groove of the synchro-hub (arrow -3-) are in line
- Heat synchro-hub for 5th and 6th gear to approximately 100°C, fit and drive on; ensure there is no play.
- Check 6th speed sliding gear for axial play.
- Line up markings (arrow-3-) on paired synchro-hub -A- and locking collar for 5th and 6th gear (arrow -1-1)
- Fit locking collar (arrow -1-) with selector fork (arrow -2-) onto synchro- hub -A- as well as follower for 5th and 6th gear -B-onto selector rod -C- at the same time.
Note:
^ Selector fork rib (arrow -2-) must face towards shaft end.
^ When sliding follower onto selector rod for 5th and 6th gear remember holes for roll pin.
- Press in roll pin -A- flush.
Note: Do not drive in roll pin, otherwise selector rod mounting will be damaged.
Re-determining shim for 5th speed gear:
- Fit spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
- When fitting circlip, push in direction of arrow onto stop.
- Measure distance between sleeve and fitted circlip with depth gauge -B-.
- Determine shim from table.
Refer to Parts Supplier
The following shims are available:
- Fit shim selected (arrow) onto hollow shaft.
- Heat 5th speed gear to approximately 120°C, fit and drive onto stop free of play.
^ Installation position: shoulder toward spacer sleeve
Re-determining circlip for 5th speed gear:
- Determine thickest circlip that can still just be fitted.
- Determine circlip from table.
Refer to Parts Supplier
The following circlips are available:
- Fit circlip.
- Drive on inner race for 5th speed sliding gear free of axial play.
- Oil needle bearing with gear oil and fit.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th speed sliding gear with spring.
- Heat 1st inner race for ball bearing for input shaft to approximately 100°C, fit onto input shaft and drive onto stop; ensure there is no play.
- Check 5th speed sliding gear for axial clearance.
Permissible axial clearance: 0.15-0.35 mm
- Insert dowel sleeves into bearing plate.
- Fit new gasket for end cover.
- Fit end cover and insert securing bolts (arrows -B-).
Note: Do not tighten bolts.
- Clean two magnets (arrows -A-) and insert.
- Fit support plate end tighten hand tight.
^ Installation position: Lugs towards magnets
- Tighten bolts for end cover using diagonal sequence.
- Oil 2nd inner race and with ball contact surface facing towards input shaft ball bearing, drive onto input shaft through hole in end cover.
- Remove support bridge 30-211 A.
- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear), do this by moving two selector plates (arrows).
- Tighten multi-point socket head bolt to 150 Nm.
- Unclip cover -3- for oil collector from oil collector -1- at longer end with a screwdriver and remove magnet -2-.
4- O-ring
5- Positioning segment
- Clean oil collector.
- Assemble oil collector.
- Guide oil collector from interior of end cover with support arm leading through hole of end cover (arrow), until O-ring can be fitted from outside onto oil collector.
- Lightly oil new O-ring and fit.
- Insert oil tube of oil collector into input shaft.
- Turn oil collector until the positioning segment is located in the machined recess of the end cover (arrow).
- Press in oil collector onto stop.
- Slide assembly sleeve, Part No. 01 E 311 120, onto selector shaft.
- Check neutral position of followers.
Selector gates must align.
- Install complete selector shaft.
- Screw locking bolts -A- for selector shaft into transmission housing.
- Aluminum and steel bolts must not be interchanged when installing.
Tightening torques: for aluminum locking bolts = 50 Nm, and for steel locking bolts = 70 Nm.
- Lightly oil new O-ring for cover for selector shaft and fit.
- Fit cover for selector shaft.
- Apply sealing paste AMV 188 000 02 to bolts -B- (Qty. 3) before installing and tighten.
- Slide Torsen differential onto splines of hollow shaft.
- Press Torsen differential in direction of arrow, and measure distance between top edge of bolted end cover and front edge of outer race of ball bearing for Torsen differential.
- Determine required shim(s) from following table.
Refer to Parts Supplier
The following shims are available:
- Insert spring plate -C- into bearing housing.
Installation position: larger diameter (concave side) towards the shims.
- Fit shims -B- as determined in table.
- Fit spring -A- to end of drive flange.
- Lightly oil new O-ring for bearing housing and fit.
- Oil small needle bearing in drive pinion.
- Insert complete bearing housing and pull home evenly.
- Tighten bearing housing using diagonal sequence.
- Fill new seal for drive axle between sealing lip and dust lip with sealing grease G52 128 A1.
- Pull a thin protective hose tightly onto splines of input shaft.
- Drive on seal for input shaft.
^ Pressing-in depth (factory): 3.5 mm
^ Pressing in depth (repairs): 4.5 mm
- Remove protective hose.
- Install release bearing, clutch release lever and guide sleeve, Refer to Clutch, MT, Service and Repair
- Check that transmission can be shifted through all gears.
- Fit connecting rod.
- Check oil level in transmission.