Components

Components - 6 Spd. Manual Transmission 0A3 All Wheel Drive

Transmission

^ Allocate bolts and other components according to transmission code.
^ Carefully clean all joints and adjacent areas before disconnecting.
^ When exchanging or repairing a manual transmission, check oil level and top off if necessary.
^ Determine capacities and specifications using the respective code letters.

Sealant

^ Thoroughly clean housing joint surfaces before applying sealing compounds.
^ Apply sealing paste AMV 188 001 02 evenly and not too thick.
^ Do not allow sealing compound to enter ventilation openings.

O-rings, seals, gaskets

^ Always replace O-rings, gaskets and seals.
^ After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
^ Thoroughly clean housing joint surfaces before assembling.





^ Before installing radial shaft seals, lightly oil outer circumference and fill space between sealing lips - arrow - halfway with sealing grease G 052 128 A1
^ Open sides of oil seals face fluid side.
^ When pressing in new gaskets, make sure sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
^ Lightly oil O-rings before installing; this prevents the rings from being crushed when inserting.
^ After replacing seals and sealing rings, check transmission fluid level and top off if necessary.

Locking elements

^ Do not over-stretch circlips.
^ Always replace circlips which have been damaged or overtensioned.
^ Circlips must be properly seated in base of the groove.





^ Replace spring pins. Installation position: Slit - A - should be in line with the line of force - arrow -.

Bolts and nuts

^ Loosen bolts and nuts in reverse of tightening sequence.
^ Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
^ Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
^ Tightening torques stated apply to unoiled bolts and nuts.
^ Replace self-locking bolts and nuts.
^ Clean threads of bolts that were applied with locking fluid using a wire brush. Apply locking fluid AMV 185 101 A1 before reinstalling.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Adjustment shims

^ Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.
^ Inspect for burrs and signs of damage.
^ Do not install shims which are damaged or not in perfect condition.

Bearings

^ Set needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward drift.
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Install various bearings (removed tapered roller bearings) into transmission, lubricated with gear oil.
^ Heat inner races of taper roller bearings to approx. 100 degree C before installing. Press on to the stop when installing, so there is no axial clearance.
^ Warm inner race for needle and roller bearings to 130 degree C max.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
^ Taper roller bearings installed on a shaft must be replaced as a set and use same make of bearings.
^ Check double angular contact ball bearing with drive pinion installed and uninstalled differential for wear (running noise). "Bearing must not catch and must run smoothly when drive pinion is turned".
^ If gear set is replaced, then always replace double angular contact ball bearing on drive pinion with it.

Synchronizer rings

^ Do not interchange. When reusing synchronizer rings, always install to the same gear.
^ Check for wear and replace if necessary.





^ Check coated friction surfaces - arrows 2 - from intermediate ring - B - for damage (flat areas, disintegrating areas or carbon layer).
^ Check inner friction surface - arrow 1 - of synchronizer ring - A - and outer friction surface arrow 4 - of inner race - C - for grooves and scoring.
^ On inner race - C - with coated friction surfaces - arrow 3 -, check coating for damage (disintegrating carbon layer).
^ Coat with gear oil before installing.

Gears and synchronizer hub

^ Before pressing on, clean and heat to max. 100 degree C on a heater.
^ When installing, press onto stop so there is no axial play.
^ Temperature can be check using temperature tester V.A.G 1558, ignition tester V.A.G 1767 or diesel tester V.A.G 1743.
^ Observe installation position.

Selector gears

^ After installing, check 1st through 6th gear for minimal amount of axial clearance of at least 0.10 mm and for ease of movement.