Transmission, Assembly
Transmission, Assembly
• Press the new grooved ball bearing - item 16 - in => [ Input Shaft Overview ] Input Shaft Overview onto the input shaft.
- Install the support bridge (T10323) as illustrated.
- Install the input shaft together and the 5th and 6th gear selector shaft with selector rod into the clutch housing.
Turn the spindle on the support bridge (T10323) and lift the input shaft - 1 - to dimension - a -.
• - a - = 15 mm
- Install the left stub shaft to the differential - A -; this way the differential can be raised in the following work steps.
- Install the differential.
A second technician is needed to perform the following work.
- Lift the differential in the - direction of the arrow - (2nd technician).
- First place the 1st and 2nd gear input shaft - 1 - with the selector shaft with selector rod - 2 - in the bearing seat and then move it toward the input shaft - 3 -.
- Lift the 1st and 2nd gear output shaft on the gear - arrow A - and swing it toward the input shaft (2nd technician).
- Guide the reverse gear output shaft - 1 - under the splines on the gear - arrow A - and place it in the bearing seat - arrow B -.
Turn the spindle on the support bridge (T10323) and lower the input shaft approximately 10 mm.
3rd and 4th Gear Selector Shaft with Selector Rod Installed Position (- 1 -)
The shorter brace - arrow - points to the clutch housing.
- Install the 3rd and 4th gear output shaft - 2 - together with the 3rd and 4th gear selector shift with selector rod - 1 -.
- Install the left stub shaft - 3 - to the differential.
- Lower the input shaft just enough - A - by turning the spindle on the support bridge (T10323) so that is remains slightly tensioned (lifted approximately 1 m).
- Place the reverse gear selector fork - A - into the reverse gear output shaft slide locking collar.
• The stud bolts - arrows - must be vertical before installing the transmission housing.
• The grooved ball bearing/input shaft only fits in one position in the transmission housing.
• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.
- Mark the flattened side with color.
- Place a mark on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (next illustration).
- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, (V.A.G 1416).
• It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.
- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.
- Align the mark on the grooved ball bearing - A - with the mark on the transmission housing - B - and install the transmission housing.
- Pay attention to the studs for the reverse gear selector shaft with selector fork.
• Do not distort the transmission housing when installing it; hold it parallel to the clutch housing.
- Install the grooved ball bearing/input shaft locking ring - 1 -.
- Remove the support bridge (T10323) from the input shaft - A -.
- Install the transmission housing to the clutch housing and tighten the bolts to specification.
• There are different bolts and tightening specifications, see - item 14 - in => [ Transmission Housing and Shift Unit ] Transmission Components Overview.
• If the bolts - B - have been removed, install them now.
- Install the stub shaft - A - with the spring, thrust washer and tapered ring.
- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold tool (T10371).
- Install the stub shaft with the spring, thrust washer and tapered ring.
- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold tool (T10371).
Install the Shift Unit as Follows:
- Turn the transmission with the opening for the shift unit in the assembly stand upward.
- Move the selector shafts with selector rods into the neutral position.
- Guide the shift unit with the shift finger - 1 - through the selector shafts with selector rods - A and B - (selector shafts with selector rods, next illustration).
Selector shafts with selector rods - A and B -.
- Rotate the shift unit in the - direction of the arrow - far enough (=> previous illustration), until it can be guided into the transmission housing.
- Then, rotate the shift unit in the - direction of the arrow - until the shift finger - 2 - points in the illustrated position.
- Install the shift unit with the shift finger into the selector shafts with selector rods - A and B - (=> previous illustration) and at the same time all the way into the transmission housing.
• It must be possible to move the gear shift shaft easily (forward and backward).
- Tighten the shift unit - B - bolts.
- Ignore the - arrow -.
- Install the backup lamp switch (F4) - A -.
- Install the nuts - C -.
- Install the trip recorder sensor (G75) - A - and bolt - arrow -, if equipped.
- Install the input shaft seal. Refer to => [ Input Shaft Seal ] Input Shaft Seal.
- Install the slave cylinder with the release bearing. Refer to => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.
- Counter hold the stub shaft using the counter hold tool (T10371) and tighten the bolts using the socket and extended bit (T10107 A).
- Move the transmission shift lever through all the gears.
- Drive the cap into the transmission housing until seated using the thrust piece (T10042)
Securing the Retainer Plate:
Threaded holes - arrows - near the plate:
- Install the retainer plate - 1 - with the three screws.
No threaded holes in the area of the plate:
- Install the retainer bracket - 2 - with the stud bolt - 1 -.
Installed position:
• The retaining bracket must be positioned above the center of the sealing cap.
For the correct bolts and other parts, refer to the Parts Catalog.