Part 1

Assembly sequence, 01E, 6 Spd. M/T AWD

Special tools and equipment:

Removing and installing bearing housing, Torsen differential, end cover, shift lever mechanism in transmission, input shaft, drive pinion and hollow shaft

Special tools and equipment
^ VW 402 Thrust plate
^ VW 407 Thrust tool
^ VW 412 Thrust tool
^ VW 415 A Tube
^ VW 447 H Thrust plate
^ VW 454 Thrust pad

Special tools and equipment (continued):

^ VW 540 Engine and transmission support
^ VW 681 Seal extractor
^ VW 771 Multi-purpose tool
^ 30-23 Extension
^ 30-100 Thrust sleeve
^ 30-211 A Support bridge

Special tools and equipment (continued):

^ 40-21 Thrust sleeve
^ 2064 Setting pin
^ 3116 Spring pin
^ 3118 Thrust piece
^ 3121 Drift
^ 3275 Internal puller

Special tools and equipment (continued):

^ Pressure device 3276

Special tools and equipment (continued):

^ -1- 2-Arm puller Kukko 20/10
^ -2- Puller hooks V/170
^ Container
^ Depth gauge

Disassembling





- Clamp transmission in VW 540 holding fixture.
- Place container under the transmission.
- Drain gear oil.





- Screw out bolts -1- and detach leaf spring -2-.
- Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-.
- Unbolt guide sleeve.





- Unscrew bearing housing -arrow- and pull off.





Bearing housing is pushed away slightly from end cover by coil spring -A- when it is being pulled off.
- When detaching bearing housing, observe installation position of dished washer -C-.
^ Installation position: Outside diameter (concave side) facing shims -B-
- Remove shims -B-, note thickness and re-determine if necessary.





- Pull Torsen differential out of end cover.





- Pull oil collector sufficiently far out of end cover -arrow- until it moves freely.





- Swivel oil collector -arrow- down and guide it out through hole of end cover.
- Remove oil collector.





- Remove locking bolts -A- for selector shaft from transmission housing.
- Remove 3 bolts -B- for cover for selector shaft, remove cover.
- Pull out selector shaft.





- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates -arrows-.





- Slacken multi-point socket head bolt -arrow B- in input shaft through hole -arrow A- in end cover and unscrew.
- Remove supporting plate.
- Remove supporting plate for needle bearing.





- Remove 2 magnets -arrows A- and clean. Slacken 5 bolts -arrows B- for attaching end cover to manual transmission and remove.





- Pull off 2nd inner race of four-point bearing (roller bearing side) for input shaft.

Note: Internal puller 3275 engages in a circular groove in the inner race when pulling off -arrow-.

- Remove end cover together with end cover/bearing plate gasket.
- Pull dowel sleeves out of bearing plate.





- Pull off 5th sliding gear and spring together with 1st inner race -A- of four-point bearing (ball bearing side) for input shaft.
B - Two-arm puller, e.g. Kukko 20/10
- Remove 5th gear synchro-ring.
- Remove circlip for 5th gear wheel.
- Lock hollow shaft in position by engaging two gears





- Pull off 5th gearwheel.

Note: Only use hexagon bolt of spring sleeve 3116, length 50 mm

C - Two arm puller, e.g. Kukko 20/10 with 200 mm hooks
- Remove shim -B- for 5th gear wheel, note thickness and re-determine if necessary.
- Remove spacer sleeve -A-.





- Press out spring pin -A- for selector fork for 5th and 6th gear.

Notes:
^ Do not damage synchro-ring for 6th gear when pressing out spring pin.
^ Do not drive out spring pin, otherwise selector rod bearing will be damaged.

- Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (until stop is felt).





- Mark relative positions -arrow 3- of locking collar for 5th and 6th gears -arrow 1- and synchro-hub -A- (paired) -arrow 1-.





- Pull follower together with selector fork and locking collar off selector rod.





- Pull off 6th sliding gear, synchro-ring for 6th gear, synchro-hub for 5th and 6th gears and inner race for 5th sliding gear needle bearing.
A - Two-arm puller, e.g. Kukko 20/10 with 200 mm hooks





- Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
- Secure drive pinion opposite hollow shaft e.g. with hose strap, to prevent it slipping out.
- Detach bearing plate with input shaft, drive pinion and hollow shaft and with shift lever mechanism in transmission from transmission housing.





- Remove circlip from selector rod for 1st and 2nd gear and remove follower -A-.
- Pull out selector rod -B- for 5th and 6th gear.
- Remove follower -C- for reverse gear.





- Pull thrust washer -arrow A- for needle bearing for 6th gear off shaft.
- Remove circlip -arrow B- for cylinder roller bearing inner race with pliers.
- Take out inner race -arrow C- for cylinder roller bearing (not a press fit).





- Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing plate.





- Unscrew hexagon bolt -D-, remove spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse idler gear.
- Take out spring, synchro-ring and reverse idler gear.
- Remove relay lever for reverse gear.

Notes:
^ Drive pinion and hollow shaft can be removed complete if it is possible to easily lever off 6th gear wheel.
^ If, however, it is necessary to press off 6th gear wheel, the drive pinion must be pulled out from hollow shaft.

- Remove temporary locking element preventing drive pinion from slipping out.





- Pull drive pinion out of hollow shaft -D- collect taper rollers -A- (23 off) when carrying out this step.
- Remove corrugated spring -B- and needle roller assembly -C-.

Note: Carefully protect mount from contamination, clean if necessary.





- Check drive pinion/hollow shaft bearing.
1 - Flange ring (conical contact surface facing taper rollers)
2 - Taper rollers (23 off) with large diameter facing drive pinion head
3 - Supporting ring (conical contact surface facing taper rollers)
4 - Corrugated spring
5 - Circlip for taper roller bearings for drive pinion





- Pressing off 6th gear wheel

Note: Because of the type of fit, it may be possible to press gear off easily.

- Remove hollow shaft or drive pinion and hollow shaft from bearing plate together with selector rod and selector fork for 1st and 2nd gears.

Assembling
- Install hollow shaft with selector fork and selector rod for 1st and 2nd gear (without follower) into bearing plate.





- Heat 6th gear to approximately 100°C and install.
- Installation position: Shoulder toward taper roller bearing

WARNING! Wear protective gloves!

- Press fully in until zero play.
- Insert taper roller bearing of drive pinion/hollow shaft with multi-purpose grease.





A - Flange ring, taper roller (23 off) and supporting ring
B - Corrugated spring
C - Needle roller assembly
D - Hollow shaft
- Oil needle bearing well.





- Insert drive pinion into hollow shaft and secure with hose strap, to prevent it from slipping down.
- Install relay lever -A- for reverse gear over relay lever bolt, paying attention to pin (for limiting movement of relay lever relevant to synchro-ring).
- Insert reverse idler gear -B- and engage relay lever with groove on reverse idler gear.





- Insert synchro-ring -C-.
^ Installation position: Position flat on synchro-ring circumference to face input shaft (not as yet installed) -arrow 1-
- Insert spring.
^ Installation position: Hook single angled end into recess on synchro-ring -arrow 2-. Turn double angled end anticlockwise and insert into opening on bearing plate -arrow 3-.
- Insert shaft for reverse idler gear -C-.
- Install retaining plate -A-.
- Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate
- Insert spring clasp -B- into locking pins of synchro-ring.
- Replace self-locking nut -D- and tighten to 25 Nm.