Transmission
Transmission
=> [ 5th Gear, Installing ]
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Needle Bearing Drift (VW 295)
• Driving Sleeve (VW 244 B)
• Hot Air Blower (V.A.G 1416)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• (M8 x 100 mm Bolt)
• Bracket (30-211A)
• Driving Sleeve (32 - 111)
• Thrust Piece (T10030/4)
• Tube 37 mm Dia. (VW 416 B)
• Puller (T10408)
• Support Bridge (T10323)
• Subframe Support Assembling Device (3253/7)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Piece (40 - 105)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Kukko Puller (80-210 mm) (18/1) (quantity: 2)
• Inductive Heater (VAS 6414)
• Sealant (AMV 188 200 03)
• M7 x 35 bolts with washers (components of the puller (T10408))
Disassembling
- Remove the clutch release lever, the release bearing and the guide sleeve. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
• Be careful not to damaged the bearing for the input and output shafts when removing and installing the 5th gear.
• When securing the transmission to the (VW 353), mount the following tools for support:
Under the Input Shaft:
• (30-211A)
• (32 - 111)
• (T10030/4)
- Secure the bolt on the (30-211A) with the nut - A -.
Under the Output Shaft Bracket
• (T10323)
• (3253/7)
• (VW 433)
- Secure the transmission on the (VW 353).
- Place the drip tray underneath.
- Open the oil fill plug and the oil drain plug.
- Drain the transmission fluid.
- Remove the transmission housing cover - arrow -.
Install the 5th gear shift fork as follows:
- Cover the openings in the transmission housing with a cloth.
- Move the shift fork - 1 - into neutral.
- Remove the bolt - 2 - with the shift jaw for 5th gear.
- Remove both bolts - arrows - for the pivot pin.
- Remove the pivot pin.
- Remove the 5th gear shift fork.
- It is not necessary to remove the spring - 3 - and the locking collar - 4 -.
- Engage the 5th gear - arrow 1 - and 1st gear - arrows 2 - and - 3 - and then remove the bolts - A - for the synchronizer hub and for the 5th gear wheel.
- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear wheel cannot turn. Both bolts can be loosened now.
• Remove any locking compound residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.
- Remove both bolts - arrows - for the reverse shaft support.
- Remove the 3rd bolt - arrow - from the reverse shaft support.
- For transmissions on vehicles with the stop/start system: remove the transmission neutral position sensor (G701) - arrow -.
- Move the shift shaft into neutral and remove the shift shaft with the shift cover. Remove the bolts - arrows - and pull the shift shaft out of the transmission housing.
- Remove the cover - A - and pivot pin - B - from the bottom of the transmission.
- Remove the pivot pins - A - on the top side of the transmission and bolts - B - for the transmission housing to clutch housing in area of differential.
- Remove the bolts - A - that connect the clutch and transmission housing.
• Do not remove the nuts - B - for the bearing mount on the output shaft.
- Remove both flange shafts.
- Remove the flange shafts with the springs, thrust washers and tapered rings.
Remove the following components together with the transmission housing:
• 5th gear synchronizer hub
• 5th gear wheel
• Both (T10408/3) must be attached to the 5th gear.
• The straps must be located above the 2 ribs on the housing, opposite each other - arrows -.
• There is a needle bearing under the 5th gear wheel.
• Secure the straps so that the needle bearing does not touch the 5th gear when removing the transmission housing.
Use the (T10408) together with the following special tools:
• (T10408/2)
• (T10408/3)
• 18/1 (quantity: 2)
- Install the (T10408) in the threaded holes in the transmission housing cover using the bolts - A -.
A M7 x 35 bolts with washers
Tightening specification 18 Nm
- Mount the (T10408/2) on the shafts.
- Install the 18/1.
- Remove the 5th gear synchronizer hub, the 5th gear and the transmission housing by tightening the spindles - A - (1/2 turn) alternating.
- Warm the 5th gear slightly using the (V.A.G 1416).
- Remove the shift forks - A - together with the shift rails.
- Remove the shift mechanism/reverse gear - B -.
- Remove the nuts - B - from the bearing mount/output shaft.
- Remove the reverse gear - A -, the input shaft - B - and the output shaft - C -, one after the other, from the clutch housing.
- Remove the differential.
Assembling
- Install the differential.
- Always replace the seals - arrows - for the bearing mount/output shaft.
• The illustration only shows 3 of the 4 seals.
- Insert the output shaft - 1 - and output shaft - 2 - together.
- Tighten the output shaft bearing mount nuts to specification, see - item 11 -=> [ Nut ] Transmission Component Overviews.
- Mount the reverse gear - 3 - on the needle bearing inside the clutch housing.
Shoulder - arrow - faces away from clutch housing.
- Make sure the reverse shaft - 4 - is complete, refer to => [ Reverse Shaft ] Reverse Shaft; do not mount the support on the reverse shaft.
- Install the reverse shaft into the clutch housing.
- Clean all threaded holes in the reverse shaft supports of locking compound; cleaning can be done with a thread tap.
- Mount the reverse shaft support.
- Install the reverse gear shift fork - 1 - with the support for the reverse gear shift fork - 2 -, the spring - 3 - and the sliding piece - 4 -.
Reverse gear location
- Install the shift mechanism/reverse gear - A -.
- Install the shift forks - B - together with the shift rails.
Reverse gear supports - C - are located in front of the selector rails.
- Install the M8 x 100 stud bolts - A - into the reverse shaft support so that the shaft is aligned after fitting the transmission housing.
- Align the shift rails.
• The shift segments must be installed in the grooves on the locking collars.
- Apply sealant (AMV 188 200 03) evenly over the sealing surface on the clutch housing.
- Install the transmission housing.
Install the bolts for the reverse shaft support - arrow - as follows:
- Install the bolt - a -.
- Remove the stud bolt - A - (=> upper illustration).
- Install the bolt - c -.
Tightening sequence:
- Tighten the bolt - a - to 30 Nm.
- Tighten the bolt - b - to 25 Nm.
- Tighten the bolt - c - to 25 Nm (=> upper illustration).
- Install the pivot pin - arrow - for the shift forks. To do this align the shift mechanism using a screwdriver, so that the relevant pivot pin can be installed.
- Apply the sealant (AMV 188 200 03) evenly on the sealing surface on the sealing cover.
- Install the shift shaft cover.
Install the shift shaft cover as follows:
- Move the shift rail into the neutral position.
- Apply the sealant (AMV 188 200 03) evenly on the sealing surface on the cover.
- Move the shift shaft into neutral.
- Position the selector shaft so that selector finger - arrow - is inserted into the selector rails.
- Tighten the selector shaft selector cover specification, see - item 17 -=> [ Bolt ] Transmission Component Overviews.
- For transmissions on vehicles with the stop/start system: install the transmission neutral position sensor (G701) - arrow - and tighten the bolt to specification, see - item 11 -=> [ Bolt ] Transmission Component Overviews.
- Install both flange shafts with springs, thrust washers and tapered rings.
5th Gear, Installing
• Make sure the (30-211A) and the (T10323) are installed.
- Secure the bolt on the (30-211A) with the nut - A -.
Installed Position, 5th Gear
The groove all the way around - arrow - faces the transmission housing.
- Warm the 5th gear to approximately 100 °C (212 °F) with the (VAS 6414).
CAUTION!
Wear safety gloves.
- Install the 5th gear.
5th Gear Synchronizer Ring, Checking
- Before reinstalling the drive gear and synchronizer ring for 5th gear, press the synchronizer ring onto the taper of the drive gear and measure the gap dimension - a - using a feeler gauge.
- Install the 5th gear selector gear with needle bearing.
- Place the 5th gear synchronizer ring onto the selector gear.
- If disassembled, assemble the 5th gear locking collar/synchronizer hub. Refer to => [ Assembling 5th Gear
Locking Collar/Synchronizer Hub ] Input Shaft.
Installed Position of 5th Gear Synchronizer Hub/Locking Collar
The pointed teeth on the locking collar - arrow 1 - and the high collar on the synchronizer hub - arrow 2 - face the transmission housing.
The notches - arrow 3 - on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring (see lower).
5th Gear Synchronizer Ring with Cast Locking Pieces
- Cover all openings with a cloth to prevent foreign objects from getting into the transmission.
- Warm the 5th gear wheel synchronizer hub to approximately 100 °C (212 °F) with the (VAS 6414).
CAUTION!
Wear safety gloves.
- Install the 5th gear synchronizer hub
• Make sure there is enough clearance when installing the synchronizer ring.
- Loosen the support for the input shaft.
- Remove locking compound residue from the threaded holes for the synchronizer hub and 5th gear drive gear bolts using a thread tap.
Otherwise, there is the danger that the screws could shear off.
- Install the synchronizer hub bolts and 5th gear.
Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Bolts
The outer diameter - arrows - faces 5th gear.
- Engage 5th gear - arrow 1 - and 1st gear - arrows 2 - and - 3 - and then tighten the bolts - A - for the synchronizer hub and the 5th gear wheel to the tightening specification. Refer to - item 4 -=> [ Bolt ] Transmission Component Overviews.
- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear wheel cannot turn. Both bolts can be loosened now.
- Install the 5th gear shift fork.
Adjusting 5th Gear
- Engage the 5th gear. Loosen the bolt - 1 -. Push the locking collar and the shift jaw in the - direction of arrow -. Tighten the bolt - 1 - to 25 Nm.
• Check measurement: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.
- Remove the 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.
- Move the shift lever (selector lever) through all the gears.
- Install the transmission housing cover. Refer to => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.
- Install the guide sleeve for the release bearing. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Fill the transmission fluid. Refer to => [ Pay attention to the
following list for the subject - ] Installing.