Part 2
Assembly sequence, 01E, 6 Spd. M/T AWD (continued)
- 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 toward follower, Item -4-
- Press inner race -arrow C- for cylinder roller bearing onto input shaft.
- Install circlip -arrow B- using 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.
- Lubricate selector rods and all bearings of input shaft and drive pinion in transmission housing and bearing plate with gear oil.
- Lever used input shaft seal carefully out of transmission housing with VW 681.
- Coat sealing surfaces between bearing plate and transmission housing with sealing paste AMV 188 001 02.
- 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 plate/transmission housing.
- Tighten bolts in diagonal sequence to 25 Nm.
- Insert locking bolts for selector rods with sealing paste AMV 188 001 02 and tighten to 50 Nm.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Install thrust washer -arrow A- for needle bearing for 6th gear.
^ Installation position: Shoulder toward circlip -arrow B-, smooth contact surface to shaft end
- Lubricate needle bearing for 6th sliding gear with gear oil and install.
- Slide on 6th sliding gear with spring and synchro-ring.
^ Installation position: The lugs of synchro-ring engage into recesses below in sliding gear.
- Support input shaft with support bridge 30-211 A.
Installation position of 5th and 6th gear synchro-hubs:
^ Side with projecting face -arrow 1- faces shaft end.
^ The input shaft oil bore -arrow 2- and the synchro-hub oil groove -arrow 3- are aligned.
- Heat synchro-hub for 5th and 6th gears to approximately 100°C, install and drive on up to stop.
WARNING! Wear protective gloves!
- Check 6th sliding gear for axial play.
^ Permissible axial play: 0.15 to 0.35 mm
- Align markings -arrow 3- on paired synchro-hub -A- and locking collar for 5th and 6th gears -arrow 1-.
- Install locking collar -arrow 1 - with selector fork -arrow 2- onto synchro-hub -A-, and at the same time install follower for 5th and 6th gears -B- onto selector rod -C-.
Notes:
^ Selector fork rib -arrow 2- must face toward shaft end.
^ When sliding follower onto selector rod for 5th and 6th gear, note holes for spring pin.
- Press in spring pin -A- flush.
Notes:
^ Do not drive in spring pin, otherwise selector rod bearing will be damaged.
^ Mount spring pin groove in direction of force as shown in illustration.
- Re-determine shim for 5th gearwheel:
- Install spacer sleeve -A- (length 39.6 mm) onto hollow shaft.
- When installing circlip, press indirection of arrow until fully home.
- Measure size between sleeve and installed circlip using depth gauge -B-.
The following shims are available
- Install selected size of shim -arrow- onto hollow shaft.
- Heat 5th gear to approximately 100°C, install and drive on up to stop.
^ Installation position: Shoulder toward spacer sleeve
WARNING! Wear protective gloves!
- Re-determine circlip for 5th gearwheel:
- Determine and attach the thickest 2nd circlip that will still just fit.
Note: Allocate circlips using spare part catalog.
Available circlips
- Install circlip.
- Drive on inner race for 5th sliding gear free of axial play.
- Oil needle bearing with gear oil and install.
- Place synchro-ring for 5th gear in locking collar.
- Slide on 5th sliding gear with spring.
- Heat 1st inner race for four-point bearing (ball bearing side) for input shaft to approximately 100°C, install onto input shaft and drive on up to stop.
WARNING! Wear protective gloves!
- Check 5th sliding gear for axial play.
- Permissible axial play: 0.15 to 0.35 mm
- Insert dowel sleeves into bearing plate.
- Install new gasket for end cover.
- Install end cover and insert securing bolts -arrows B-.
Note: Do not tighten bolts at this stage.
- Clean 2 magnets -arrow A- and insert.
- Insert supporting plate and tighten by hand.
^ Installation position: Lugs face magnets.
- Tighten bolts for end cover in diagonal sequence.
- Lubricate 2nd inner race for four-point bearing (roller bearing side) and insert onto input shaft with track for ball facing four-point bearing of input shaft and drive over 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 2 selector plates -arrows-.
- Tighten multi-point socket head bolt to 150 Nm.
- Check neutral position of followers.
^ Gear gates must align.
- Use screwdriver to unclip cover for oil collector -3- from oil collector -1- at long end and remove magnet -2-.
4 - O-ring
5 - Positioning segment
- Clean oil collector.
- Assemble oil collector.
- Guide oil collector, with supporting arm ahead, from interior of end cover through hole of end cover sufficiently far -arrow-, so that the new O-ring can be installed onto oil collector from outside.
- Lightly oil new O-ring and insert.
- Insert oil pipe of oil collector in input shaft.
- Rotate oil collector until positioning segment is positioned in milled recess of end cover -arrow-.
- Press in oil collector onto stop.
- Slide assembly sleeve -A-, Part No. 01E 311 120, onto selector shaft -B-.
- Install complete selector shaft.
^ Installation position: Flat of selector shaft faces downward
- Insert locking bolts -A- for selector rod with sealing paste AMV 188 001 02 and tighten to 50 Nm.
- Lightly oil new O-ring for selector shaft cover and install.
- Install cover for selector shaft.
- Install bolts -B- (x3) with sealing paste AMV 188 001 02 and tighten to 25 Nm.
- Push Torsen differential onto splines of hollow shaft.
- Press Torsen differential in direction of arrow; measure distance between top edge of bolted end cover and front edge of outer race of ball bearing for Torsen differential.
- Determine shim(s) required according to table.
The following adjustment shims are available:
- Insert dished washer -C- into bearing housing.
^ Installation position: Large diameter (concave side) facing shims
- Install shims determined from table -B-.
- Install spring -A- onto end of flanged shaft.
- Lightly oil new O-ring for bearing housing and insert.
- Oil small needle bearing in drive pinion.
- Insert complete bearing housing and pre-tighten evenly.
- Tighten bolts in diagonal sequence.
- Pack space between sealing lip and dust lip of new seal for input shaft with sealing grease.
- Pull a thin protective hose tightly onto splines of input shaft.
- Tap in input shaft seal.
^ Insertion depth: 3.5 mm
Note: Insertion depth for repairs is 4.5 mm when a used input shaft is employed.
- Remove protective hose.
- Install release bearing, clutch release lever and guide sleeve.
- Select all gears.
- Install connecting rod.
- Top off manual transmission with gear oil and check oil level.