Assembly Sequence
Assembly sequence
Disassembling and assembling transmission housing cover, transmission housing, selector mechanism, input shaft, output shaft (pinion shaft), differential and selector forks Special tools and workshop equipment required
^ VW 309 Holding plate
^ VW 353 Transmission support
^ VW 295 Drift
^ VW 244 B Fitting sleeve
^ V. A. G. 1416 Hot air blower
^ Studs M8 x 100 mm
Disassembling
- Mount transmission on repair stand.
- Drain transmission oil.
- Remove clutch release lever and release bearing
- Remove guide sleeve.
- Remove transmission housing cover (arrow).
- Remove 5th gear selector fork (arrow).
- Remove bolts - A - for synchro - hub and 5th gear, to do this select 5th (arrow 1) and 1st gear (arrows 2 and 3).
- After engaging both gears the input shaft and output shaft are locked, synchro - hub and gear cannot turn. Both bolts can now be loosened.
- Pull off synchro - hub and 5th gear and remove together with needle roller bearing.
- A - Two arm puller e.g. Kukko 20/10 with MatraV/170 hooks
- B - Hexagon bolt M10 x 20
- Pull off 5th gear
- A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks
- B - Hexagon bolt M10 x 20
- Sequence for removing: fit two arm puller and center by turning screw (arrow). Heat gear with hot air blower V.A.G 1416 and pull off.
Notes: When pulling off the gear ensure that the hooks do not bend outward, if necessary tighten screw (arrow). After 5th gear has been removed, check for damage.
- Remove both drive flanges.
- Take out drive flanges along with springs, thrust washers and tapered rings.
- Remove both reverse shaft support bracket bolts (arrows).
- Remove selector shaft with selector mechanism cover. To do this, place selector shaft in neutral position. Then remove bolts (arrows) and pull selector shaft out of the transmission housing.
- Remove cover plate - A - and pivot pins - B - from underside of transmission.
- Remove pivot pins - A - on top side of transmission and transmission housing to clutch housing securing bolts - B - in area of differential.
- Remove bolts - A -, from inside clutch housing for securing clutch housing to transmission housing.
Notes: Do not remove nuts - B - for output shaft bearing support.
- Take off transmission housing, if necessary carefully lever up all around and alternating between sides on the protruding housing flange (arrows), being careful not to damage sealing surfaces.
- Remove selector forks - A - together with selector plates.
- Unscrew bolt for selector mechanism for reverse gear - B -.
- Remove nuts for output shaft bearing support
- Remove reverse gear - A -, input shaft - B - and output shaft - C - one after the other from clutch housing.
- Take out differential.
Assembling
- Install differential.
- Always replace sealing rings (arrows) for output shaft bearing support.
Notes: The illustration only shows 3 of the 4 sealing rings.
- Install input shaft, output shaft and reverse shaft together.
- Tighten nuts for output shaft bearing support.
- Clean locking fluid residue from threads in the reverse shaft support (arrow Illustration V34 2293, Pace 34-72). The residue can be removed using a tap.
- Install reverse shaft support.
- Install reverse gear selector mechanism. Installation position of reverse gear.
- Install selector forks together with selector plates.
- Screw M8 x 100 mm studs - A - into reverse shaft support so that the shaft is aligned after fitting transmission housing.
- Align selector plates.
Notes: The selector segments must be positioned in the grooves on the locking collars.
- Fit transmission housing.
Install reverse shaft support bolts (arrow) as follows:
- Insert bolt - a -, remove stud (Illustration V34 2008), insert bolt - b - and tighten by hand. - Tightening sequence:
^ 1 tighten bolt - a - to 30 Nm
^ 2 tighten bolt - b - to 30 Nm
- Install pivot pin (arrow) for selector forks. To do this, align selector mechanism with a screwdriver, so that the relevant pivot pin can be installed.
- Fit selector shaft cover.
Install selector shaft as follows:
- Place selector plates in neutral.
- Locate lug (arrow 1) in the recess in transmission housing. Position selector shaft so that selector finger (arrow 2) is inserted in the selector plates.
- Install selector shaft cover.
Installation position 5th gear
The circumferential groove (arrow) faces to transmission housing.
- Knock - on 5th gear.
Checking 5th gear synchro O-ring
- Before installing 5th gear and synchro O-ring press the synchro O-ring onto the cone of the gear and measure gap - a - with a feeler gauge.
- Install 5th gear with needle roller bearing
- Place 5th gear synchro O-ring on gear
- Assembly 5th gear synchro - hub/locking collar before installing.
Installation position 5th gear synchro - hub/locking collar
The pointed teeth of the locking collar (arrow 1) and the high shoulder of the synchro - hub (arrow 2) face the transmission housing.
The synchro - hub mountings (arrow 3) align with the synchro O-ring cast locking pieces.
5th gear synchro O-ring with cast locking pieces (arrows)
- Knock - on 5th gear synchro - hub.
Notes: When driving on ensure synchro O-ring is free to move.
- Screw - in securing bolts for synchro - hub and 5th gear.
Installation position of dished washers for gear and 5th gear synchro - hub securing bolts:
The outer diameter (concave side - arrows -) faces 5th gear.
- Engage two gears before tightening 5th gear synchro - hub and gear securing bolts (arrows) (Illustration 34-2613).
- Install 5th gear selector fork.
Adjusting 5th gear:
- Engage 5th gear. Loosen bolt - 1 -. Press locking collar and selector fork jaws in direction of arrow, then tighten bolt -1- to 25 Nm.
- Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear. If necessary, repeat adjustment.
- Disengage 5th gear. Locking collar must now be in the neutral position. Synchro -ring must move freely.
- Select all gears.
- Fit transmission housing cover.
- Install drive flanges along with springs, thrust washers and tapered rings.
- Fit release bearing guide sleeve.
- Fit clutch release lever and release bearing.