Transmission, Assembly Sequence
Transmission, Assembly Sequence
Input shaft bearing, end cover, center differential, transmission cover, selector shaft and bearing housing with input shaft and pinion/hollow shaft, removing and installing.
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Pressure Plate (VW 401)
• Pressure Plate (VW 402)
• Punch (VW 412)
• Sleeve (VW 415 A)
• Thrust piece (VW 433)
• Sleeve (VW 519)
• Engine and Transmission Holder (VW 540)
• Press Tube (30 - 23)
• Seal Driver-Front Wheel Bearing (40 - 21)
• Sleeve (40 - 103)
• Thrust piece (40 - 105)
• Drive Bushing (41 - 501)
• Transmission Holder (2004)
• Lock Pin (2064)
• Thrust Piece (3002)
• M8 and M10 Bolt (3114/2)
• Pressure Application Device (T10246)
• Workshop Press (V.A.G 1290 A)
• Drip Tray (V.A.G 1306)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Internal Puller (Kukko 21/2)
• Puller (Kukko 18/2)
• Plate (T40086)
• Plate (T40088/1)
• Sleeve (T40088/2)
• Attachment (V.A.G 1582/12)
• Two Arm Puller (Kukko 20/10)
• Puller Hooks, 200 mm Long
• Puller Hooks, 250 mm Long
• Heat Gun (V.A.G 1416)
• Feeler Gauge
• 2, M8 Bolts, 70 mm Long with Washers
• Sealing Paste (AMV 188 001 02)
• Assembly Sleeve (01E 311 120)
• Thread Locking Compound (AMV 185 101 A1 )
- Mount transmission in assembly fixture.
- Place Drip Tray (V.A.G 1306) under transmission.
- Drain gear oil.
- Remove clutch release lever - A - with release bearing.
- Remove guide sleeve - B -.
- Then remove plate spring - C -.
- Circlip - D - in front of ball bearing of input shaft must then be removed.
- Note thickness of circlip, if the input shaft or transmission housing is not replaced.
- Remove input shaft ball bearing from transmission housing.
- Remove circlip - arrow - behind input shaft ball bearing.
- Note thickness of circlip, if the input shaft or transmission housing is not replaced.
- Remove the bolts - arrows - and remove center differential housing - A -.
• Only 4 of the 6 bolts are shown in the illustration.
- Remove the center differential and pressure spring from the pinion/hollow shaft.
- Remove the bolts - arrows - and remove selector shaft cover - A -.
- Remove both selector shaft locking bolts - 1 -.
• Make sure a gear is not engaged.
- Slide the selector shaft - 2 - into transmission all the way and remove the dowel pin - 3 -.
- Pull out selector shaft.
- Secure the input shaft by engaging 2 gears, for example, reverse and 1st gear, by moving 2 selector rods - arrow A - and - arrow B -.
- Remove the transmission cover bolts - A - and the bearing housing - B - on the transmission housing - C -.
- Carefully remove the transmission cover to the rear. The bearing housing must remain attached to the transmission housing.
• Always replace the O-ring - arrow - from the transmission cover.
- Secure the bearing housing to the transmission housing with two M8, 70 mm bolts and washers - arrows -.
- Tighten both bolts to maximum 10 Nm.
- Remove oil collector tray - A -.
- Remove input shaft internal multi-point bolt - 1 -.
- Remove the 6th gear wheel with the roller bearing inner race and thrust washer.
A Two Arm Puller, e.g. (Kukko 20/10)
• Check the splines on the gears for damage after removing.
- Remove synchronizer ring and 6th gear needle bearing.
- Remove 6th gear wheel.
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 200 mm
- Remove spacer sleeve from the hollow shaft.
- Remove dowel pin and clamp - A - for the 5th and 6th gear shift fork circlip from the selector shaft - B -.
• Mark the installation position of the locking collar on the synchronizer hub - arrow -.
- Move shift fork - C - downward and remove the locking collar - D -.
- Warm the 5th and 6th gear synchronizer hub - arrow - with a Hot Air Gun (V.A.G 1416) to approximately 100° C.
- Remove the 5th gear wheel together with the 6th gear inner race/needle bearing and 5th and 6th gear synchronizer hubs.
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 200 mm
• When doing this, counterhold on the Two-Arm Puller, for example, with a open-ended wrench - B -.
• If the 6th gear inner race/needle bearing contacts the Thrust Pad (VW 433), insert the Lock Pin (2064 ) into the hole in the input shaft to be able to remove the components completely.
- Remove the 5th gear wheel
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 250 mm
• The 5th gear wheel and be removed at the same time with the 4th gear wheel.
- Remove 4th gear wheel
A Extractor, for example, (Kukko 18/2)
• Counterhold on the Extractor - A -, for example, with the Transmission Holder (2004).
- Remove the 4th gear wheel together with the 5th inner race/needle bearing and thrust washer.
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 200 mm
- When doing this, counterhold on the Two-Arm Puller, for example, with a open-ended wrench - B -.
- Remove the synchronizer ring and 4th gear needle bearing.
- Remove the dowel pin and clamp - A - for the 3rd and 4th gear shift fork circlip from the selector shaft - B -.
• Mark the installation position of the locking collar on the synchronizer hub - arrow -.
- Remove the shift fork - C - and locking collar - D -.
- Remove the 3rd and 4th gear synchronizer hubs and make note of the circlip thickness.
Remove the 3rd gear wheel together with the 3rd and 4th gear synchronizer hub.
A Extractor, e.g. ( Kukko 18/2)
• Counterhold on the Puller - A -, for example, with the Transmission Holder (2004) so that the Removal Plate (T40086) does not come in contact with the 3rd gear wheel or the selector rod for 5th and 6th gears.
- Remove the locking ring for the 3rd gear wheel needle bearing and then remove the needle bearing.
- Remove the thrust washer - B - for the 3rd gear wheel.
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 250 mm
- Remove support/reverse shaft bolts - arrows -.
- Secure the pinion from falling out, for example, with a hose clamp - A -.
- Remove the 2 bearing housing bolts - B - on the transmission housing and then remove the bearing housing.
- Remove hose clamp from the pinion.
- Remove needle bearing - A - for the pinion - B - and pull the pinion out of the hollow shaft - C -.
- Place an Internal Puller - A -, for example, (Kukko 21/2) into the hole in the support/reverse shaft.
- Expand the Internal Puller far enough so that it touches the support/reverse shaft - B -.
- Carefully remove the support/reverse shaft from the bearing housing in direction of - arrow - and with the reverse gear wheel.
- Remove the 3rd gear wheel circlip and make a note of the circlip thickness.
- Remove the 3rd gear wheel
A Two Arm Puller, e.g. (Kukko 20/10) with Puller Hook 250 mm
- Carefully remove the input shaft - A - at an angle forward form the bearing housing in direction of - arrow -.
- Remove the dowel pin and clamp - A - for the reverse gear shift fork circlip from the selector shaft - B -.
• Mark the installation position of the locking collar on the synchronizer hub - arrow -.
- Remove the shift fork - C - and locking collar - D -.
- Remove the reverse gear synchronizer hub from the hollow shaft.
• Place the bearing housing on the Thrust Plate (VW 401) and (VW 402) in such a way so that the hollow shaft and the selector rods do not get damaged when the synchronizer hub is being removed.
- Remove the reverse gear wheel, the reverse gear wheel needle bearing and the reverse gear synchronizer hub.
- Guide the hollow shaft out of the 1st and 2nd gear shift fork and bearing housing.
Transmission, Assembling. Refer to => [ Transmission, Assembling ] Transmission, Assembling