020 Transmission Assembly
NOTE: The transmission is assembled in reverse order of disassembly. Pay particular attention to the following points:
- Installation position of 1st gear thrust washer:
^ Shoulder (A) on inner diameter faces the bearing cover (B).
- Installation position of operating sleeve/synchronizer hub for 1st/2nd gear: the groove on face (A) and outside teeth on operating sleeve (B) face 1st gear (C).
- Heat 1st/2nd gear operating sleeve/synchronizer hub to approximately 100°C (212°F), then place in position and drive firmly into place while turning synchronizer ring so that the grooves align with keys.
- Install reverse idler gear, driving shaft in gently if necessary.
- Drive the inner race of 2nd gear needle bearing on to stop.
Available Circlips:
- Adjust axial clearance on 3rd gear by Determining the thickest circlip that can be inserted (reference table for sizes), and install.
NOTE: Part numbers are listed for reference only.
NOTE: If the input shaft has not been disassembled:
^ Press off deep groove ball bearing.
- Install assembled input shaft without bearing. Input shaft is supported by bridge 30-211 A, needle bearing drift VW 295 A and M12 lock nut. 020 Transmission Disassembly
NOTE: Vehicles with 2.0 liter 85 kW (115 hp) engine are equipped with an additional circlip (A).
- Install 4th gear on output shaft and secure with circlip.
^ Installation position of 4th gear: shoulder (arrow) faces toward splines (A) for 5th gear.
- Press in deep groove ball bearing for input shaft.
^ Installation position: wide shoulder (arrow) on inner race faces press tool.
- Install tension bracket (arrow).
NOTE: The tension bracket only fits in one position. The bolts must be tightened again after the transmission housing is installed.
- Before installing shift fork set, insert lower spring (arrow) for selector rod into clutch housing.
- Install shift fork set and align shift jaws.
^ (A) is 1st/2nd gear shift fork, Arrow points toward recess for bridge (C).
^ (B) is 3rd/4th gear shift fork.
^ (C) is bridge with 5th gear shift tube.
^ (D) is reverse gear shift fork.
- Slide selector rod into position.
- Align reverse idler gear shaft.
NOTE: Distances -x- are identical.
- Drive on transmission housing.
- Install Torx(r) bolt for reverse idler gear shaft. Tightening torque: 20 Nm (15 ft lb).
- Install hex-head bolts to secure housing. Tightening torque: 25 Nm (18 ft lb).
- Tighten bolts for deep groove bearing tension bracket. Tightening torque: 15 Nm (11 ft lb).
- Heat 5th gear to approximately 100°C (212°F) and install.
^ Installation position: groove (arrow) faces upward (circular groove on vehicles with 2.0 liter engine).
- Install thrust washer and circlip.
NOTE: Circlip for 5th gear on vehicles with 2.0 liter, 85kW (115 hp) engine is replaced by a securing plate, ref (A).
- Install synchronizer hub for 5th gear complete with operating sleeve, gear, shift fork for 5th gear and new securing plate.
- Use tube wrench 3059 to screw shift tube clockwise into shift lock.
- Thread shift tube back out to adjust projection -x-. Dimension -x- = 5.0 mm (0.197 in).
CAUTION: DO NOT extract the selector rod from the shift tube (e.g. with an incorrectly aligned tube wrench). Otherwise, the shift forks could come apart inside, making it necessary to disassemble the transmission again. If necessary insert a screwdriver through the slot in the side to hold the selector rod while removing the slot wrench.
- Engage 5th gear and reverse gear (front shift jaw down).
- Coat threads of new synchronizer hub bolt with VWD6 locking fluid and tighten using 12 mm 12-point socket-head wrench. Tightening torque: 150 Nm (111 ft lb).
- Move shift fork to neutral position.
- Insert selector shaft (1).
- Install selector shaft spring (2) and cover (3).
- Tighten cover (3). Tightening torque: 50 Nm (47 ft lb).
NOTE: If the cover was sealed with a seal ring (4), it should also be replaced (part no. N 903 54301 ref. only).
- Install lock bolt for selector shaft with sealant, part no. AMV 188 20003. Tightening torque: 40 Nm (30 ft lb).
- The 5th gear selector fork is adjusted as follows:
NOTE: Perform this adjustment with the greatest care to prevent the transmission from jumping out of gear:
- Check protrusion of shift tube. Use 3059 tube wrench to adjust if necessary. Dimension -x- = 5.0 mm (0.197 in.).
- Bolt gear selector shaft lever onto selector shaft and engage 5th gear (pull lever out to stop and turn to left).
- Raise the operating sleeve together with the shift fork slightly (to compensate for free play in linkage components).
- Align operating sleeve (1) with selector fork (2) so there is no free play to 5th gear (3).
- Clearance -a- must exist between operating sleeve and 5th gear.
- Dimension -a- = 1.3 mm (.051 in).
- If necessary, adjust dimension -a- by turning selector tube.
- Disengage 5th gear.
- Operating sleeve must be in neutral position.
- Synchronizer ring must move freely.
- Support shift fork using tools (A) approximately 12 mm (0.47 in) thick (e.g. two open-end wrenches, 19 mm and 24 mm).
- Drive on new securing plate.
- Before installing the cover (arrow):
- Install new gasket (where applicable).
- Release tension on input shaft support bridge.
- Starting at 5th gear end, guide clutch pushrod into input shaft.
- Install clutch release bearing on clutch push rod.
- After installing cover:
^ Shift through all gears to make sure they engage correctly.
- Install drive flanges.