Disassembly and Assembly Sequence
Disassembly and assembly sequence, 012/01W, 5 SPD. M/T
Input shaft ball bearing, multi-function sensor, input shaft, drive pinion, shift rods and transmission cover, disassembling and assembling.
Special tools, testers and auxiliary items required:
^ Holding Plate VW 309
^ Transmission Support VW 353
^ Press Device 3235
^ Triple Square Socket Driver 3357
^ Taper Roller Bearing Puller VAG 1582
^ Gripping Piece VAG 1582/2
Special tools, testers and auxiliary items required
Drip tray VAG 1306:
Torque Wrench 5-50 Nm V.A.G. 1331:
Disassembling
Note:
^ To remove the above-mentioned components, it is not necessary to remove the differential.
^ Removal is only necessary when adjustments have to be performed.
^ Place appropriate drip tray V.A.G 1306 underneath transmission.
^ Drain transmission fluid using Triple Square Socket Driver 3357.
^ Clamp transmission in assembly fixture.
^ Remove clutch release lever - A - with release bearing.
Note:
^ To protect oil seal, pull heat-shrinkable tube over splines of input shaft before pulling off
^ Remove guide sleeve - B -.
^ Remove dished washer - C -.
^ Remove circlip - D - in front of input shaft ball bearing.
^ Note thickness of circlip, if ball bearing, input shaft or transmission housing is not replaced.
^ Pull input shaft ball bearing out of transmission housing.
^ Remove circlip - arrow - behind input shaft ball bearing.
^ Note thickness of circlip, if ball bearing, input shaft or transmission housing is not replaced.
^ Unthread transmission cover - A - from transmission housing - B -.
^ Remove bolts - arrows - and multi-function sensor.
^ Remove bolts for relay shaft - arrows -.
^ Unbolt shift detent - arrow - and swing it out.
^ Input shaft - A -, drive pinion - B -, relay shaft - C -, shift rods - D - with selector shaft and selector forks - E - must be carefully removed together.
Installing
If the input shaft ball bearing, input shaft or transmission was replaced, the thickness of the circlips for the input shaft must be re-determined.
^ Swing transmission housing into position shown.
^ Thus, the following components can be installed more easily.
^ Assemble input shaft - A -, drive pinion - B -, relay shaft - C -, selector rods - D - with shift rod and selector forks - E -.
^ Install these components into transmission housing as a set.
Note:
^ Relay shaft - C - and shift rod can also be installed later following illustrations N34-0585 and V34-3120.
^ Move transmission housing and engage 3rd gear - direction of arrow -.
^ Install relay shaft - A -.
^ Place shift rod - B - sideways into mounting hole in transmission housing and assemble into mounting eye.
^ Carefully turn shift rod in - direction of arrow -.
^ Insert shift detent and tighten bolt - arrow - securely.
^ Thread in bolts for relay shaft - arrows-.
^ Replace O-ring for multi-function sensor.
^ Carefully insert multi-function sensor and tighten - arrows -.
Check whether the alignment bushings are installed in the transmission housing - B - for the transmission cover - A -.
^ Install transmission cover - A - on transmission housing - B -.
^ Install rear circlip - arrow - for input shaft ball bearing.
^ Slide ball bearing onto input shaft.
Installed position:
Closed side of ball bearing cage faces toward transmission housing.
^ Press in ball bearing:
Slide thrust pad - A - of Press Device 3235 onto input shaft.
Place press device behind splines for clutch disc. Pre-tension bolts - B -. The bolts bear against the recesses in thrust pad - A -.
Press in ball bearing by alternately tightening bolts (1/2 turn at a time) until stop.
^ Install front circlip - D - for input shaft ball bearing.
^ Place dished washer - C -
Installed position:
Convex side faces guide sleeve - B -
Note:
^ To protect oil seal, pull heat-shrinkable tube over splines of input shaft before pressing on.
^ Install guide sleeve - B - for clutch release bearing
^ Install clutch release lever - A - with release bearing.