Components
Components
Transmission
• You can find information about code letters, aggregate allocation, gear ratios and capacities in the repair information. Refer to => Manual Transmission [1][2]Manual Transmission/Transaxle
• 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.
• For procedure for removing and installing shaft seals in an installed transmission, refer to and to => Transmission and Drivetrain Transmission and Drivetrain
• After replacing seals and sealing rings, check transmission fluid level and top off if necessary.
Locking Elements
• Do not overstretch circlips.
• Always replace circlips which have been damaged or over tensioned.
• 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 specifications stated apply to non-lubricated 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 approximately 100 °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 °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 °C on a heater.
• When installing, press onto stop so there is no axial play.
• Temperature can be check using temperature tester ( VAG 1558), ignition tester (VAG 1767) or diesel tester (VAG 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.