Components
Components
Transmission
• Allocate bolts and other components according to transmission code letters. [ Code, Transmission Allocation, Ratios and Capacities ] Code, Transmission Allocation, Ratios and Capacities.
• When changing a transmission, check oil level and add oil if necessary. Refer to => [ Manual Transmission, Checking Gear Oil Level ] 02XA Transmission.
• Capacities and specifications. Refer to => [ Code, Transmission Allocation, Ratios and Capacities ] Code, Transmission Allocation, Ratios and Capacities.
• When installing a new rear final drive, check the oil level in the rear final drive and fill if necessary. Allocation. Refer to => [ Rear Final Drive 01R ] Rear Final Drive 01R, => [ Rear Final Drive 0AR ] Rear Final Drive 0AR or => [ Rear Final Drive 08V ] Rear Final Drive 08V.
• Thoroughly clean all connections and the surrounding area before disconnecting.
• When installing transmission, make sure that the alignment bushings are installed correctly.
Sealant
• Thoroughly clean housing joint surfaces before applying sealing compounds.
• Apply Sealing Paste (AMV 188 001 02 ) evenly and not too thick.
• Do not allow sealing compound to enter ventilation openings.
O-rings, Gaskets, Seals
• O-rings, gaskets and seals must be replaced.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Thoroughly clean housing joint surfaces before assembling.
• Before installing radial shaft seals, lightly oil outer circumference and fill space between sealing lips - arrow - halfway with Sealing Grease (G 052 128 A1).
• The open side of the gaskets points toward the fluid to be sealed in.
• When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
• After replacing seals and gaskets, check and, if necessary, top off oil level in final drive. Refer to => [ Manual Transmission, Checking Gear Oil Level ] 02XA Transmission.
Fasteners
• Do not over-stretch circlips.
• Always replace damaged or over-stretched circlips.
• Circlips must locate properly in the groove.
• Replace spring pins. Installation position: Slit - A - should be in line with the line of force - arrow -.
Bolts and Nuts
• Loosen bolts and nuts in reverse order of tightening sequence.
• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
• Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with Locking Fluid (AMV 185 101 A1 ).
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
Adjusting Shims
• Use a micrometer to measure the shims at several points. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Do not install shims which are damaged or not in perfect condition.
Mount
• Install new tapered roller bearing as supplied and do not use additional oil.
• Install various bearings (removed tapered roller bearings) into transmission, lubricated with gear oil.
• Heat inner races of tapered roller bearings to approximately 100 °C before installing. Press on to the stop when installing, so there is no axial clearance.
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
• Tapered roller bearings installed on a shaft must be replaced as a set and use same make of bearings.
• Install needle bearings with lettered side (thicker metal) towards fitting tool.
• Grease rear transmission input shaft needle bearing in flywheel.
Synchronizer Rings
• When reusing synchronizer rings, do not interchange and always install to the same gear.
• Check for wear and replace if necessary.
• Check coated friction surfaces - arrows 2 - from intermediate ring - B - for damage (flat areas, disintegrating areas or carbon layer).
• Check the inner friction surface - arrow 1 - of the synchronizer ring - A - and the outer friction surface - arrow 4 - of the inner race - C - for "grooves " and "scoring".
• On inner races - C - with coated friction surfaces - arrow 3 -, check coating for damage (disintegrating carbon layer).
• Coat with gear oil before installing.
Gears and Synchronizer Hub
• Before pressing on, clean and heat to max. 130 °C on a heater.
• When installing, press onto stop so there is no axial play.
• The temperature can be checked with either the Emissions Testing Station (VAS 6300) or the Ignition Tester (V.A.G 1767).
• Observe installation position.
Selector Gears
• After installing, check 1st through 6th gear for minimal amount of axial clearance and for ease of movement.
Damage on the selector gears and locking collars
• Damage to the synchronizer ring or gear wheel:
A Worn clutch spline camber on the synchronizer ring or gear wheel
• In comparison: synchronizer ring or gear wheel not damaged:
B Worn clutch spline camber on the synchronizer ring or gear wheel
• Picture of damage on the locking collar:
C Worn longitudinal inner spline camber and the locking collar
• In comparison: locking collar undamaged
D Undamaged longitudinal inner spline camber and the locking collar
Hydraulic
• When removing transmission, remove clutch slave cylinder without disconnecting lines.
• If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise, the piston will be pressed out of the clutch slave cylinder. The clutch slave cylinder will thereby be damaged.
• If the clutch pedal does not return to the starting position (rest position) after recoupling it, bleed the clutch system. Refer to => [ Master Cylinder and Slave Cylinder General Information ] Description and Operation.
• Bleeding the clutch system should be performed in intervals with the bleeding of the brake system.
• Observe assembly instructions for SAC pressure plate. Refer to => [ Clutch with SAC Pressure Plate ] Clutch With SAC Pressure Plate.
• On vehicles with SAC pressure plate, an adjusting ring must be reset if only the clutch plate is being replaced. Refer to => [ SAC Clutch Pressure Plate Adjuster Ring, Adjusting ] Adjustments.
• To reduce odor caused by a burnt clutch, thoroughly clean the clutch bell housing, the flywheel and the side of the engine facing toward the transmission.