Assembly Sequence
Assembly Sequence - 6 Spd. Manual Transmission 0A3 All Wheel Drive
Note:
^ You do not need to remove the differential when removing the components listed above.
^ Removal is only necessary when adjustments have to be performed.
Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Transmission support VW 353
^ Tube VW 415 A
^ Tube VW 421
^ Slide Hammer-Complete Set VW 771
^ Driver 32 - 111
Special tools, testers and auxiliary items required
^ Thrust piece 40 - 105
^ Drive bushing 41 - 501
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Puller T40054
^ - 1 - Two arm puller Kukko 20/10
^ - 2 - Puller hooks, 250 mm long
^ Feeler gauge
^ Sealing paste AMV 188 001 02
^ Assembly sleeve 01E 311 120
^ Thread locking compound AMV 185 101 A1
^ Sealing grease G 052 128 A1
^ Depth gauge, e.g. Digital Depth Gauge VAS 6087
^ Oil receptacle
Special tools, testers and auxiliary items required
^ Socket and key T40097
Transmission, disassembling
- Place an oil receptacle underneath transmission.
- Drain gear oil.
- Secure transmission to assembly stand with bolts - arrows -.
- Tilt transmission on assembly stand to horizontal position.
- Loosen bolt - 1 - and remove leaf spring - 2 -.
- Remove clutch release lever - 3 - with release bearing.
- Remove bolts - arrows - and remove securing plate - 1 -.
- Pull guide sleeve - 2 - out of transmission housing.
- Remove intermediate piece - 3 - from transmission housing.
- Pry out O-ring - arrow - with a small screwdriver.
- Circlip - arrow - in front of grooved ball bearing of input shaft must then be removed.
Note:
^ To disassemble transmission, you do not need to remove the input shaft grooved ball bearing.
^ A faulty input shaft grooved ball bearing can be released in a removed but not disassembled transmission according to the procedure.
- Move shift shaft to neutral position.
- Remove both securing bushings - A - for selector shaft.
Note:
^ Identify these securing bushings so that they are not interchanged with the securing bushings for the selector rods.
^ The securing bushings were changed shortly after series production.
- Remove bolts - arrows - and remove selector shaft cover - B -.
- Slide selector shaft - A - into transmission up to stop and pull out dowel pin - B -.
- Pull out selector shaft.
- Remove bolts - arrows - and remove torsen housing.
- Remove torsen differential from drive pinion/hollow shaft.
- Remove circlip - 1 - and shim(s) - 2 - from drive pinion
Note:
^ Note the thickness of the circlip and shim(s).
- Remove inner race - 3 - and outer race - 4 -. These components are push fit and can be installed by hand.
- Remove spacer ring - 5 - from twelve-point nut on hollow shaft.
- Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.
- Loosen twelve-point nut on hollow shaft with socket and key T40097.
A - Torque wrench.
- Shift selector rods into neutral position.
- Turn transmission in assembly bracket so transmission cover faces up.
- Remove bolts - arrow 1 - (for securing bearing bracket), bolt - arrow 2 - (for securing reverse shaft) and connection screws - A - for transmission cover on transmission housing.
Note:
^ Always replace the O-ring - C -.
- Remove reverse gear - 1 - and reverse shaft.
- Remove clutch hub - 2 - with synchronizer ring for reverse gear by hand.
Remove magnet - 3 - from transmission housing.
- Remove securing bushings - 1 - to - 4 - for selector rods.
- Remove locking collar - A - with shifter fork - B - and reverse gear selector gear - C -.
- Remove thrust washer and selector gears for reverse gear and 1st gear.
- Remove 1st gear selector gear with needle bearing and synchronizer rings.
- Remove 2nd gear selector gear - C - together with inner race for 1st gear selector gear - D - and shifter fork for 1st/2nd gear - B - from hollow shaft.
A - Two arm puller, e.g. Kukko 20/10 with puller hook 250 mm
- Remove bearing bracket - A - with reverse shaft mount - B -.
- Remove oil pan - C - from transmission housing.
- Then guide hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - upward over the drive pinion - arrow -.
- Remove bolts - arrows - and retainer plate - A - with shim lying below "S4".
- Carefully remove drive pinion - 1 - from bore in transmission housing - 2 -.
Double angular contact ball bearing outer races - 3 - and - 4 - must not be pulled apart, otherwise the double angular contact ball bearing seal - 6 - can be damaged by the drive pinion face - 5 -. In this case, double angular contact ball bearing must be replaced.
Transmission, assembling
If transmission housing, gear set or hollow shaft was replaced, you must first redetermine the thickness of the shim "S6". It is located on the hollow shaft and is responsible for position 2nd gear selector gear.
If gear set is replaced, then always replace double angular contact ball bearing on drive pinion with it.
To check double angular contact ball bearing for wear (running noise), differential must be removed. When turning the installed drive pinion, the bearing must not catch and must run smoothly.
Note:
^ All threaded bores in which self-locking bolts are threaded must be carefully cleaned of remaining locking fluid using a tap.
^ Clean threads on hollow shaft for twelve-point nut.
^ Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.
^ Housing joint surfaces must be cleaned.
^ Checking synchronizer rings for wear.
- Place shim "S3" in transmission housing.
- Coat outer races - 3 - and - 4 - with transmission fluid.
- Carefully slide drive pinion - 1 - with double angular contact ball bearing by hand into transmission housing - 2 - and press onto upper outer race - 3 - at the same time.
Note:
^ Warm transmission housing beforehand with a hot air gun in bearing seat area, if necessary.
Outer races - 3 - and - 4 - must not tilt when inserting, they must remain together. Otherwise, the seal - 6 - can be damaged by the pinion face - 5 -.
If the double angular contact ball bearing seal is damaged, the bearing must be replaced.
- Insert shim "S4" and retainer plate - A -, only fits in one position.
- Clean threads of previous screws - arrows - with a wire brush. Then insert screws with locking compound AMV 185 101 A1 and tighten in diagonal sequence to 30 Nm.
- Place hollow shaft needle bearing on drive pinion.
- Insert hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - in transmission housing and at the same time, guide hollow shaft over drive pinion - arrow -.
- Place oil pan - 1 - with ridge - arrow A - in notch - arrow B - in transmission housing.
- Guide bearing bracket - A - over input shaft and hollow shaft and place on oil pan - C -.
Reverse shaft mount - B - must be installed on bearing bracket.
Synchronizer rings for 1st, 2nd and reverse gears, checking for wear
- Check inner race on outer friction surface arrow for scoring or signs of wear, replace if necessary.
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Place inner race, intermediate ring and synchronizer ring on selector gear taper or clutch hub taper and screw in.
Note:
^ Screw in means: Turn synchronizer ring approx. one turn while pressing on the ring at the same time.
- Then measure gap - a - with a feeler gauge.
Note:
^ Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
Differentiation of reverse gear synchronization rings - A - and 1st/2nd gear - B -
1. Synchronizer ring for reverse gear: tabs arrow 1 have a smooth surface.
2. Reverse gear intermediate ring: friction surfaces arrow 2 are coated with sintered linings (brass colored).
3. Reverse gear inner race: has no inner friction surface arrow 3.
4. Synchronizer ring for 1st and 2nd gear: tabs have 2 ridges each arrow 4.
5. Intermediate ring for 1st and 2nd gear: friction surfaces arrow 5 are coated with carbon (black).
6. Inner race for 1st and 2nd gear: inner race arrow 6 is coated with carbon (black).
Installation location of synchronizer rings for 1st and 2nd gear as well as reverse gear
Note:
^ If the components are not to be replaced, make sure they are reallocated to their original gear.
^ Do not interchange reverse gear synchronizer rings with 1st and 2nd gear synchronizer rings.
- Place inner race - 2 - on selector gear - 1 - or clutch hub.
- Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
- Insert synchronizer ring - 4 -. Guide tabs - C - through recess - arrow -.
- Place 2nd gear selector gear together with needle bearing and synchronizer rings on hollow shaft.
- Then attach 1st and 2nd gear synchronizer hub.
1st and 2nd gear locking collar installation location
^ Side with asymmetrical splines - arrow - must face toward 2nd gear.
Assembly of locking collar/synchronizer hub for 1st and 2nd gear
- Place locking collar - A - together with shifter fork for 1st/2nd gear - C - over synchronizer hub - B -.
Note:
^ The locking collar only fits in one position over the synchronizer hub, the splines - arrow 1 - and - arrow 2 - have different widths. Remove synchronizer hub - B - from hollow shaft and rotate, if necessary.
- Then place thrust piece in synchronizer hub notches and push thrust piece in direction of - arrow 3 - into locking collar notches. Locking collar must be held in middle position.
- Warm 1st gear selector gear inner race/needle bearing - 1 - to approx. 100 degree C, attach and drive on to stop.
Assemble locking collar and reverse gear selector gear
1. Gear wheel for reverse gear
2. Locking collar
3. Thrust piece
- Slide locking collar over reverse gear selector gear.
Installation position:
^ Pointed teeth - arrow A - in locking collar point opposite reverse gear selector gear drive splines - arrow B -.
^ Thrust piece notches - 3 - in reverse gear selector gear - arrow C - and locking collar - arrow D - must align.
- Then place thrust piece in reverse gear selector gear notches and press thrust piece in locking collar notches.
- Then place 1st gear selector gear - C - with needle bearing and synchronizer rings on inner race/needle bearing.
- Place thrust washer for 1st gear and reverse gear on hollow shaft.
- Attach reverse gear selector gear - A - (with locking collar mounted) together with reverse gear selector rod - B -.
- Place reverse shaft - 1 - with notch - arrow A - on tab - arrow B - on reverse shaft mount - 2 -.
- Place reverse gear - 1 - with needle bearing in reverse shaft, when doing so, reverse gear splines must face toward reverse gear selector gear.
- Place clutch hub - 2 - with needle bearing and synchronizer rings on hollow shaft.
- Place magnet - 3 - in transmission housing rib.
- Bring selector rods into neutral position - arrow -.
- Drive on selector rod securing bushings - 1 - to - 4 - with tube VW 421 to stop.
Note:
^ Do not interchange securing bushings for selector rods and selector shaft.
- Check whether or not there are 2 alignment pins in transmission cover for centering transmission cover/housing.
- Apply sealing paste AMV 188 001 02 evenly and not to thick on transmission housing joint surfaces at transmission cover.
- Place transmission cover - B - on transmission housing. Do not screw in screws - A - yet.
- Hand-tighten bolt - arrow 2 - in reverse shaft.
- Hand-tighten new bolts - arrow 1 - in bearing bracket.
- Then tighten the 13 bolts - A - to 24 Nm.
- Then tighten bolts - arrows 1 - to 27 Nm and bolt - arrow 2 - to 24 Nm.
- Coat new O-ring - C - with transmission fluid and insert in surrounding groove in transmission cover.
- Then rotate transmission horizontally in assembly bracket.
- Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.
- Then tighten twelve-point nut hollow shaft to 75 Nm.
A - Torque wrench
- Then shift selector rods into neutral position.
- Turn transmission in assembly bracket with transmission cover upward.
- Place spacer ring - 5 - on hollow shaft twelve-point nut.
- Install inner race - 4 - and outer race - 3 -. These components are push fit and can be removed by hand.
If you have replaced the drive pinion (gear set), you must redetermine the thickness of the circlip - 1 - and shim(s) - 2 - for tapered roller bearing on drive pinion.
Determine thickness of circlip - 1 - and shim(s) - 2 - as follows:
- Measure a gap of 0.10 mm max. between the shim available as a replacement part and circlips, measured between shim - 2 - and inner race/tapered ball bearing - 4 -.
- Check gap with a feeler gauge - 3 -.
Note:
^ When measuring, the circlip - 1 - must be fully seated in groove and inner race/tapered ball bearing - 4 - pushed in direction of - arrow -.
- Determine shim(s) and circlip according to table.
The following shims are available:
The following circlips are available:
- Install determined shim(s) and circlip.
- .
Slide torsen differential on hollow shaft splines and press in direction of - arrow -.
- When doing so, measure distance - a - from flat surface of outer race/tapered ball bearing - 1 - to flat surface of flange/transmission cover.
Determine spline needed according to table.
The following shims are available:
Note:
^ Allocate adjustment shims.
- Turn transmission horizontally in assembly bracket.
- Place plate spring - B - in torsen housing - A -.
^ Plate spring installation location: The inner diameter camber faces toward flange shaft in torsen housing.
- Place determined shim - C - on plate spring - B -.
- Place spring - D - on flange shaft in torsen housing.
- Then place torsen housing on transmission cover.
- Tighten bolt - arrow - to 24 Nm.
- Push assembly sleeve 01E 311 120 - A - onto selector shaft - B -.
Note:
^ To prevent damage to the seal - C -, the installation of the seal and selector shaft must only be performed with the assembly sleeve 01E 311 120 - A -.
^ Selector rods must be in neutral position.
- Install complete selector shaft.
^ Installation position: Flattened part of selector shaft faces downward.
- Slide selector shaft - A - into transmission up to stop and insert dowel pin - B - at the same time.
Note:
^ On dowel pin version with pins, pin side must be inserted into hole in transmission housing.
- Install cover - B - with new O-ring.
- Clean screw threads - arrows - with a wire brush. Then insert screws with locking compound AMV 185 101 A1 and tighten to 24 Nm.
A - Selector shaft securing bushings
Note:
^ Only install version - B - selector shaft securing bushings with edged collar - arrow 2 -.
^ On transmission with version - A - selector shaft securing bushings installed, these must always be replaced with version - B -.
^ If version - B - is installed, this can be reused.
- Drive in selector shaft securing bushings with tube VW 421 until they stop.
- Circlip - arrow - in front of grooved ball bearing of input shaft must then be installed.
- Coat new O-ring - arrow - with transmission fluid before installing in surrounding groove in transmission housing.
- Pull a thin insulating hose or heat-shrinkable hose over input shaft splines.
- Fill space between sealing lip and dust lip on sealing ring in guide sleeve halfway with grease G 052 128 A1.
- Lightly lubricate outer circumference of guide sleeve.
- Slide guide sleeve - 2 - over input shaft in transmission housing.
- Remove insulating hose or heat-shrinkable hose.
- Attach securing plate - 1 -.
- Clean bolt threads - arrows - with a wire brush. Then insert bolts with locking compound AMV 185 101 A1 and tighten to 24 Nm.
- Insert intermediate piece - 3 - in transmission housing.
- You must lightly coat contact surface of clutch slave cylinder plunger with copper paste before installing clutch release lever - 3 -.
- Install clutch release lever with release bearing.
- Clean bolt threads - 1 - with a wire brush.
- Place leaf spring - 2 - on screws - 1 -.
- Then insert bolts - 1 - with locking compound AMV 185 101 A1 and tighten to 24 Nm.
- Shift through all gears.