Shift Forks, 3rd Through 6th Gear
Shift Forks, 3rd through 6th Gear
- Attach transmission to assembly stand. Refer to => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.
- Place Drip Tray (V.A.G 1306) under transmission.
- Open the oil drain plug - 1 - and drain the transmission fluid.
- Install and tighten the oil drain plug - 1 -. Tightening specification => [ (Item 9) Oil drain plug ] Bearing Housing Assembly Overview.
Transmission with R tronic
- Remove the shift actuator for the R tronic. Refer to => [ Shift Actuator, R Tronic ] Shift Actuator, R Tronic.
- Remove both the hydraulic unit and the reservoir. Refer to => [ Hydraulic Unit ] Hydraulic Unit - Removing.
Manual transmission
- Remove bolts - 1 through 3 -.
- Remove both the shift unit - 4 - and the shift/selector relay lever.
Continuation for all transmission
- Engage two gears. Push the selector rods - 2 and 3 - to the right with a screwdriver.
- Remove the bolts - arrow - and remove the end cover.
- Open the peening on both nuts - arrows -.
- Remove the spring pins - 1 - with a drift.
- Remove nuts - 1 - and - 2 - with the Hexagon Spanner Head (T40208).
- Remove both the reverse drive gear - 3 - and thrust washers.
- Remove washer - 1 -.
- Remove the locking collar with synchronizer hub - 2 - and shift fork - 3 -.
- Remove the synchronizer ring - 4 -, reverse gear gear wheel - 5 - and needle bearing - 6 -.
- Remove the reverse gear wheel - 7 -, use an assembly lever if necessary.
- Remove nut - A -.
- Remove the bolts - arrows - and remove the transmission housing - B -.
Remove the 3rd through 6th gear shift fork as follows:
• Now check the locking collars for wear. Refer to => [ Locking Collar for 3rd to 6th Gears, Checking
for Wear ] Description and Operation.
• If a locking collar is worn, replace it. To do this the transmission must be completely disassembled. Refer to => [ Transmission, Assembly Sequence ] Disassembly and Assembly.
• Repairing the shift forks alone (as described following) would not be logical.
Manual transmission
- Remove the centering bolt - A -.
Transmission with R tronic
- Remove the locking pins - B - with a drift.
All
- Pull the shift rod - 1 - out of the shift forks - 2 and 3 - in direction of - arrow -.
- Remove the 5th and 6th gear shift fork - 2 -.
- Remove the 3rd and 4th gear shift fork - 3 -.
• Check shift forks for wear and replace if necessary. Refer to => [ Checking 3rd to 6th Gear Shift Forks for Wear ] Shift Forks and Shift Rails Assembly Overview.
Transmission, assembling
Install in reverse order, paying attention to the following:
- Housing joint surfaces must be cleaned.
Manual transmission
- Install the centering bolt - A - with Locking Compound (D 197 300 A2) and tighten. Tightening specification => [ (Item 4) Centering bolt ] Shift Forks and Shift Rails Assembly Overview.
Transmission with R tronic
- Install the locking pins - B -.
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
- Position the transmission housing - B - and tighten the bolts - arrows -. Tightening specification => [ (Item 1) Bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Tighten the nuts - A -. Tightening specification => [ (Item 19) Nut ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Mount the needle bearing - 6 -, reverse gear gear wheel - 5 - and needle bearing - 4 -.
- Remove the locking collar with synchronizer hub - 2 - and shift fork - 3 -.
- Mount the washer - 1 -.
- Install the reverse gear wheel - 7 -.
- Place the thrust washer with the anti-twist mechanism - arrow A - into the recess in the transmission.
- Install the reverse gear guide wheel so that the oil pump drive pin - arrow C - fits into the groove on the guide wheel - arrow B -.
- Engage two gears. Push the selector rods - 2 and 3 - to the right with a screwdriver.
- Remove both the reverse drive gear - 3 - and thrust washers.
- Tighten the new nut - 1 - with the Hexagon Spanner Head (T40208). Tightening specification => [ (Item 27) Nut ] Reverse Gear Assembly Overview.
- Tighten the new nut - 2 - with the Hexagon Spanner Head (T40208). Tightening specification => [ (Item 15) Nut ] Reverse Gear Assembly Overview.
- Caulk the nuts - arrows -.
- Install the spring pins - 1 - with a drift.
- Install the thrust washer - 1 - so that the anti-twist mechanism is in the center between the holes - 2 - and - 3 -.
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
- Mount the end cover and tighten the bolts - arrows -. Tightening specification => [ (Item 1) Bolt ] Reverse Gear Assembly Overview.
- Bring the selector rods in the transmission into the position shown.
• The openings in the selector rod yokes - 1 through 4 - must align.
• Alignment sleeves (quantity: 2) installed.
Manual transmission
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
• Bolt - 1 through 3 - tightening specifications. Refer to => [ Shift Unit on Manual Transmission Assembly Overview ] Shift Unit on Manual Transmission Assembly Overview.
• The transmission shift lever is in the neutral position - 4 -.
- Install the shift unit - 4 -.
- Mount the shift/selector relay lever with the screws - 1 and 2 -.
Transmission with R tronic
- Install the shift actuator for the R tronic. Refer to => [ Install the shift actuator. ] Shift Actuator, R Tronic.
- Install the hydraulic unit and reservoir. Refer to => [ Hydraulic Unit, R Tronic Assembly Overview ] Hydraulic Unit, R Tronic Assembly Overview.
Continuation for all transmission
- Fill gear oil. Refer to => [ Transmission Capacities ] 086A (R-Tronic) or Manual Shift Transmission.