General Repair Notes
General Repair Notes:, 01A, 5 SPD. M/T (AWD)
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, are summarized under the term "components".
Components
Transmission
^ Allocate bolts and other components via the Electronic Parts Catalog (ETKA)
^ When installing transmission, make sure centering sleeves are correctly seated between engine and transmission.
^ When replacing manual transmission or rear final drive, gear oil must be filled to lower edge of filler hole.
^ Capacity in manual transmission.
^ Capacity in rear final drive.
^ Specification of oil for manual transmission and oil for rear final drive Electronic Parts Catalog (ETKA).
Seals, sealing rings
^ Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
^ Apply sealant uniformly but not too thick.
^ Replace O-rings.
^ Radial shaft seals.
Before installing:
Lightly coat outside circumference, fill space between sealing lips - arrow - halfway with sealing grease G 052 128 A1.
After installing:
Check gear oil level in manual transmission; top off to lower edge of filler hole if necessary, specification.
Check gear oil level in rear final drive; top off to lower edge of filler hole if necessary, specification.
Circlips
^ Replace circlip.
^ Do not over-stretch circlips.
^ Circlips must be fully seated in groove.
^ Replace roll pins. Installation position: Slot is longitudinal to line of force.
Nuts, bolts
^ Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.
^ Do not cant, and loosen and tighten especially sensitive parts - e.g. clutch pressure plates, in diagonal sequence in stages.
^ Tightening torques as specified are for unoiled nuts and bolts.
^ Always replace self-locking nuts and bolts.
Bearings
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the drift.
^ Replace as a set tapered roller bearings which sit on one shaft. If possible, use same manufacturer!
^ Heat inner races to approximately 100°C to install.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
Shims
^ Measure shims at several points using a micrometer. Different tolerances make it possible to measure the required shim size exactly.
^ Check for burrs and signs of damage.
^ Only install perfect shims.
Synchronizer rings
^ Do not interchange. If re-using, allocate synchronizer rings to the same gear as before.
^ Check for signs of wear; replace if necessary.
^ Lubricate with transmission fluid before installing.
Gear wheels
^ Before pressing on, clean and heat to approximately 100°C on a heater.
^ Temperature can be checked using temperature tester V.A.G 1558.
Selector gears
^ Check selector gears of 1st to 5th gears for slight axial play or for ease of movement after installing.
Clutch control
When removing transmission, remove clutch slave cylinder without disconnecting lines.
^ If clutch slave cylinder is removed with hydraulic line connected, do not press clutch pedal any longer. Otherwise, piston will be pressed out of clutch slave cylinder. This destroys the clutch slave cylinder.
^ If clutch pedal does not return to rest position after clutch engagement procedure, check clutch master and clutch slave cylinders for function
^ Bleeding the clutch system should be performed in intervals along with bleeding the brake system.
^ Do not cant clutch pressure plate; loosen and tighten in a diagonal sequence and in stages.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission in order to reduce the smell of burnt linings.