Disassembling and Assembling Sequence
Disassembling and assembling sequence, 01X, 6-Speed Front-wheel Drive M/T
Removing and installing ball bearing for input shaft, selector shaft, transmission cover and bearing housing with input shaft and pinion shaft.
Special tools, testers and auxiliary items required
^ Drift sleeve VW 244 B
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Thrust disc VW 412
^ Tube 60 mm dia. VW 415 A
^ Thrust pad con. VW 433
Special tools, testers and auxiliary items required
^ Sleeve VW 519
^ Holding fixture VW 540
^ Press tube 30 - 23
^ Press tool 40 - 21
^ Sleeve 40 - 103
^ Thrust piece 40 - 105
Special tools, testers and auxiliary items required
^ Drift sleeve 41 - 501
^ Transmission support 2004
^ Mandrel 2064
^ Thrust piece 3002
^ Door hinge alignment tool (M8 and M10) 3114/2
^ Fitting tool T10246
Special tools, testers and auxiliary items required
^ Repair press V.A.G 1290 A
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Taper roller bearing puller V.A.G 1582
^ Adapter V.A.G 1582/12
^ - 1 - Internal puller Kukko 21/2
^ - 2 - Puller Kukko 18/2
Special tools, testers and auxiliary items required
^ Removal plate T40086
^ Holding plate T40088/1
^ - 1 - Two-arm puller Kukko 20/10
^ - 2 - Puller hook, length 200 mm
^ - 2 - Puller hook, length 250 mm
^ Feeler gauge
^ 2 bolts M8 (length 70 mm) with washers
^ Sealing paste AMV 188 001 02
^ Assembly sleeve 01E311120
^ Locking fluid AMV185101A1
Disassembling transmission
- Mount transmission on assembly stand.
- Place drip tray V.A.G 1306 under transmission.
- Drain transmission oil.
- Remove clutch release lever - A - together with release bearing.
- Remove guide sleeve - B -.
- Remove dished spring - C -.
- Remove circlip - D - in front of ball bearing for input shaft.
Note:
^ If the input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
- Pull ball bearing for input shaft out of transmission housing.
- Remove circlip - arrow - behind ball bearing for input shaft.
Note:
^ If the input shaft or transmission housing is not to be replaced, note the thickness of the circlip.
- Remove bolts - arrows - and selector shaft cover - A -.
- Remove two locking bolts - 1 - for selector shaft.
^ Make sure that no gear has been engaged.
- Push selector shaft - 2 - into transmission as far as it will go, simultaneously removing pin - 3 -.
- Remove selector shaft.
- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).
- Remove securing bolts for transmission cover - arrows -.
- Carefully remove transmission cover - A - toward rear. The bearing housing - B - remains installed to transmission housing - C -.
- Secure bearing housing to transmission housing - arrows - with two bolts M8 (length approx. 70 mm) and washers.
- Tighten 2 bolts - arrows - to max. 5 Nm.
- Detach oil collector - A -.
- Check that the 2 gears are still engaged and then unscrew and remove multi-point socket head bolt - 1 - for input shaft.
- Detach 6th speed selector gear with inner race for roller bearing and thrust washer.
A - Two-arm puller, e.g. Kukko 20/10
Note:
^ Check the gear teeth on the selector gears and gear wheels for damage after pulling them off
- Remove synchro-ring and needle bearing for 6th speed selector gear.
- Remove 6th gear wheel.
A - Two-arm puller, e.g. Kukko 20/10
- Remove spacer sleeve from output shaft.
- Pull out pin with clip - A - for securing selector fork for 5th and 6th gear from selector rod - B -.
^ Mark installation position of locking collar in relation to synchronizing hub - arrow -.
- Move selector fork - C - downward and detach with locking collar - D -.
- Remove 5th speed selector gear together with needle bearing inner race for 6th gear and synchronizing hub for 5th and 6th gear.
A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm
Note:
^ Counter-hold two-arm puller using e.g. open end wrench - B -.
^ If the needle bearing inner race for 6th gear is in contact with press tool VW 433, insert locking pin 2064 into hole in input shaft to pull off the components all the way.
- Remove 4th and 5th gear wheels together.
A - Puller, e.g. Kukko 18/2
Note:
^ Counter-hold puller - A - using e.g. transmission bracket 2004.
- Remove 4th speed selector gear with needle bearing inner race for 5th gear and thrust washer.
A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 200 mm
- Counter-hold two-arm puller using e.g. open end wrench - B -.
- Remove synchro-ring and needle bearing for 4th speed selector gear.
- Pull pin with clip - A - securing selector fork for 3rd and 4th gear out from selector rod B -.
^ Mark installation position of locking collar in relation to synchronizing hub - arrow -.
- Detach selector fork - C - with locking collar - D -.
- Remove circlip for 3rd gear and 4th gear synchronizing hub and note thickness of circlip.
- Pull off 3rd speed selector gear with synchronizing hub for 3rd and 4th gear.
A - Puller, e.g. Kukko 18/2
Note:
^ Counter-hold puller - A - using e.g. transmission bracket 2004 to prevent plate T40086 from making contact with 3rd gear wheel or selector rod for 5th and 6th gear.
- Remove circlip for 3rd speed selector gear needle bearing and detach 3rd gear needle bearing.
- Pull off thrust washer - B - for 3rd speed selector gear.
A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm
- Remove circlip for 3rd gear wheel and note thickness of circlip.
- Pull off 3rd gear wheel.
A - Two-arm puller, e.g. Kukko 20/10 with puller hook, length 250 mm
- Remove bolts - arrows - for reverse shaft support.
- Remove 2 bolts - A - for bearing housing at transmission housing.
- Remove bearing housing - B - together with shafts.
- Insert an internal puller - A - e.g. Kukko 21/2 into bore for reverse shaft support.
- Spread open internal puller far enough for it to make contact with reverse shaft support - B -.
- Drive reverse shaft support carefully out of bearing housing direction of - arrow - and remove with reverse gear wheel.
- Pull out input shaft - A - carefully from bearing housing at an angle from the front direction of - arrow -.
- Pull pin with clip - A - for securing selector fork for reverse gear out from selector rod - B -.
^ Mark installation position of locking collar in relation to synchronizing hub - arrow -.
- Detach selector fork - C - with locking collar - D -.
- Press off synchronizing hub for reverse gear from output shaft.
Note:
^ Place the bearing housing onto thrust plates VW 401 and VW 402 so that the output shaft and selector rods are not damaged when pressing off the synchronizing hub.
- Detach reverse selector gear, needle bearing for reverse selector gear and reverse gear synchronizing hub.
- Guide output shaft out of selector fork for 1st and 2nd gear and bearing housing.
Assembling transmission
If the input shaft or the transmission housing have been replaced, you must first redetermine the thickness of the input shaft circlips.
Note:
^ Lubricate all needle bearings with gear oil before installing.
^ Check synchro-rings for wear
^ Insert spring in selector gear
^ Heat gear wheels, needle bearing inner races and synchronizing hubs to 130° C (max.) before pressing on (wear protective gloves).
- Insert output shaft in bearing housing and selector fork for 1st and 2nd gear.
- Place reverse gear selector gear with needle bearing, spring and synchro-ring onto output shaft.
^ The lugs on synchro-ring should engage into recesses in selector gear.
- Press on reverse gear synchronizing hub.
^ Installation position: high inside collar faces 3rd gearwheel.
- Check axial clearance of reverse selector gear.
- Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an angle toward the rear.
- Install reverse gear wheel and tighten 3 bolts - arrows - for reverse shaft support to 30 Nm.
Assembly overview - reverse gearwheel
- Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse gear synchronizing hub.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
^ The chamfer on locking collar faces reverse selector gear.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
- Place plate T40088/1 on press table and insert bearing housing with shafts and selector rods.
- Press on 3rd gear wheel.
^ Installation position: machined side faces reverse gear synchronizing hub.
- Insert circlip for 3rd gear wheel.
^ When replacing gear wheel or output shaft:
Re-determine thickness of circlip for 3rd gear wheel:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Press on thrust washer - A - for 3rd speed selector gear until limit stop.
- Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto input shaft.
- Install 3rd speed selector gear with spring and synchro-ring.
^ The lugs on synchro-ring should engage into recesses in selector gear.
- Press on heated synchronizing hub for 3rd and 4th gear
^ Installation position: high inside collar faces 3rd speed selector gear.
- Insert circlip for synchronizing hub for 3rd and 4th gear.
^ When replacing synchronizing hub or input shaft:
Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Check axial clearance of 3rd speed selector gear.
- Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and synchronizing hub for 3rd and 4th gear.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.
Note:
^ Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm) into selector fork for 3rd and 4th gear.
- Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd and 4th gear - B -.
- Press on heated inner race - C - for needle bearing for 5th speed selector gear.
- Check axial clearance of 4th speed selector gear.
- Heat 4th gear wheel and press on.
^ Installation position: high inside collar faces 5th gearwheel.
- Heat 5th gear wheel and press on.
^ Installation position: high inside collar faces 4th gear wheel.
- Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.
^ The lugs on synchro-ring should engage into recesses in selector gear.
- Install and press on heated synchronizing hub for 5th and 6th gear.
- Check axial clearance of 5th speed selector gear.
- Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for 5th and 6th gear.
^ The markings on locking collar and synchronizing hub - arrow - must coincide.
- Move selector fork for 5th and 6th gear - C - into selector rod - B -.
- If holes of selector fork and selector rod coincide, clip in pin with clip - A -.
- Press on heated inner race for needle bearing for 5th speed selector gear.
- Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A -.
- Heat inner race - B - for needle roller bearing and press on.
- Check axial clearance of 6th speed selector gear.
- Install spacer sleeve - A - onto output shaft.
- Heat 6th gear wheel and press on.
Insert circlip - A - for 6th gear wheel.
^ When replacing gear wheel or output shaft:
Re-determine circlip - A - for 6th gear wheel:
- Determine thickest circlip that will just fit and install it.
The following circlips are available:
- Remove bearing housing from holding plate T40088/1.
- Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows - and washers.
- Tighten these 2 bolts - arrows - to max. 5 Nm
Note:
^ Do not install oil collector - A - at this stage.
- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).
- Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
- Remove complete bearing housing from transmission housing.
- Check if the 2 dowel sleeves are installed between transmission housing and bearing housing.
- Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between transmission housing and bearing housing.
- Install bearing housing onto transmission housing.
- Clip oil collector - A - into reverse shaft support.
Note:
^ Make sure that the bolts - arrows - are removed.
- Check if the 2 dowel sleeves are installed between bearing housing - B - and transmission cover - A -.
- Apply sealing paste AMV 188 001 02 evenly and not too thickly onto contact surfaces between bearing housing and transmission cover.
- Insert securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C -.
- Tighten bolts - arrows - to 35 Nm plus an additional 90° 1/4 turn.
- Push assembly sleeve 01E31/120 - A - onto selector shaft - B -.
Note:
^ To avoid damaging the oil seal - C -, the oil seal and selector shaft must only be installed using assembly sleeve OIE311120 - A -.
- Move selector rods to neutral.
- Install complete selector shaft.
^ Installation position: Chamfer of selector shaft points downward.
- Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.
^ Installation position for pin - 3 - : The groove - arrow - on pin points toward selector shaft cover.
- Clean threads of locking bolts - 1 - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 45 Nm.
- Install cover - A - with new O-ring.
- Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 24 Nm.
- Install rear circlip - arrow - for input shaft ball bearing.
- Then push ball bearing onto input shaft.
Installation position:
The sealed side of ball cage faces transmission housing.
- Pressing in ball bearing:
First screw door hinge alignment tool (M8 and M10) 3114/2 into tapped hole for ball head stud.
Slide thrust plate T10246/2 onto input shaft.
Position fitting tool T10246/1 behind splines for clutch plate. Tighten bolts - A - only slightly. The bolts locate in recesses in the thrust plate T10246/2.
Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).
- Install front circlip - D - for input shaft ball bearing.
- Install dished spring - C -.
Installation position:
The curved side faces guide sleeve - B -.
- Install a shrink hose onto input shaft splines.
- Install guide sleeve - B - for release bearing.
- Remove shrink hose.
- Install clutch release lever - A - with release bearing.
- Select all gears.