Disassembly and Assembly Sequence
Disassembly and Assembly Sequence
Removing and installing transmission housing cover, clutch housing, shift rod with shift cover, input shaft, output shaft (pinion shaft), differential and shift mechanism.
Special tools, testers and auxiliary items required
• Holding plate (VW 309)
• Transmission support (VW 353)
• Drift (VW 295)
• Driving sleeve (VW 244 B)
• Heat gun (V.A.G 1416)
• Torque Wrench (V.A.G 1331)
• (Stehbolzen M 8 x 100 mm)
• Bracket (30-211A)
• Driver (32 - 111)
• Thrust piece (T10030/4)
• Puller (T10309)
• Puller (T10040)
• with pulling hook (T10040/2)
• Torque Wrench (V.A.G 1332)
Removing
- Remove clutch release lever, release bearing and guide sleeve --> [ Clutch Release Mechanism, Servicing ] Service and Repair
- Secure transmission to retaining plate (VW 309).
• If 5th gear synchronizer hub will be removed and re-installed later in the work process, input shaft bracket (30- 211A) must also be installed at the same time when transmission is attached.
• Input shaft may be supported by driving sleeve (32 - 111) only at a later time.
- Place drip tray (V.A.G 1306) underneath.
- Open oil filler bolt and oil drain bolt.
- Drain gear oil.
- Remove transmission housing cover - arrow -.
Install 5th gear shifter fork as follows:
- Cover openings with a rag.
- Move shift fork - 1 - into neutral position.
- Remove bolt - 2 - with shift jaw for 5th gear.
- Then remove both bolts - arrows - for the pivot pins.
- Pull out pivot pins.
- Remove shift fork.
- Spring - 3 - locking collar - 4 - do not need to be removed.
- Remove synchronizer hub and 5th gear drive gear bolts - A - and insert 5th gear - arrow 1 - and 1st gear - arrow 2 - and - arrow 3 -.
- After engaging both gears, the input shaft and output shaft are locked, synchronizer hub and gear-wheel cannot turn. Now both bolts can be loosened.
• If the shafts will not be replaced, the threaded bores must be carefully cleaned of locking fluid residue using a thread tap.
Remove 5th gear synchronizer hub together with locking collar and locking pieces.
Use puller (T10309)
- First insert puller (T10309/1) between 5th gear drive gear - A - and 5th gear shifter fork mount - B -.
• Puller (T10309/1) must be placed below synchronizer ring.
- Puller must be pressed into end position, if necessary.
- Rotate puller (T10309/1) on opposite side in direction of - arrow -.
- Insert puller in threaded insert (T10309/3).
- Then install second puller (T10309/1) and place tube (T10309/2) on tool.
- Check synchronizer hub after pulling for damage.
- Replace synchronizer ring.
- Remove 5th gear selector gear with needle bearing.
- Pull off gear-wheel for 5th gear.
- First install pulling hook - A -.
B Hex bolt AF 17 M10 x 20
• When remove drive gear, ensure hook does not bend outward. Check 5th gear for damage after removing.
- Remove both flange shafts.
- Remove flange shafts with springs, thrust washers and tapered rings.
- Remove both bolts - arrows - for reverse shaft support.
- Now remove 3rd bolt - arrow - for reverse shaft support.
- Remove selector shaft with selector cover, to do this place selector shaft in neutral position. Then remove bolts - arrows - and pull shift rod out of transmission housing.
- Remove sealing cap - A - and pivot pins - B - on underside of transmission.
- Remove bolts - B - that serve to fasten the transmission housing from inside the clutch housing.
• Do not remove nuts - B - for output shaft bearing mount.
- Remove pivot pins - A - on top side of transmission and bolts - B - for transmission housing to clutch housing in area of differential.
- Remove transmission housing; if necessary, carefully pry up on the protruding housing flanges all round and alternating between sides - arrows -, do not damage sealing surfaces while doing this.
- Remove shift forks - A - together with shift rails.
- Unfasten reverse gear selector mechanism - B -.
- Remove nuts - B - for output shaft bearing mount
- Remove reverse gear - A -, input shaft - B - and output shaft - C - one after the other from clutch housing.
- Remove differential.
Installing
- Set differential in place.
- Always replace seals - arrows - for output shaft bearing mount.
• The illustration only shows 3 of the 4 seals.
- Insert output shaft - 1 - and output shaft - 2 - together.
- Tighten output shaft bearing mount nuts to specified torque --> [ 11 Nut, 25 Nm and turn 90° further ] Input Shaft and Pinion Shafts, Differential and Shift Forks.
- Place reverse gear drive gear - 3 - on needle bearing in clutch housing.
Shoulder - arrow - faces away from clutch housing.
- Check whether reverse shaft - 4 - is complete --> [ Reverse Shaft ] Reverse Shaft; do not place reverse shaft supports on reverse shaft yet.
- Reverse shaft, inserting in clutch housing
- Clean all threaded holes in reverse shaft supports of locking compound; cleaning can be done with a thread tap.
- Install reverse shaft support.
- Install reverse gear shift fork - 1 - with reverse gear shift fork support - 2 -, spring - 3 - and sliding piece - 4 -.
Reverse gear location
- Fasten reverse gear selector mechanism - A -.
- Install selector forks - B - together with selector rails.
Reverse gear supports - C - are located in front of selector rails.
- Bolt M 8 x 100 mm studs - A - into reverse shaft support so that the shaft is aligned after fitting gearbox housing.
- Align shift rails.
• The shift segments must be positioned in the grooves on the locking collars.
- Apply sealant (AMV 188 200 03) evenly onto sealing surface of the clutch housing.
- Install transmission housing.
Install bolts for reverse shaft support - arrow - as follows:
- Insert bolt - a -
- Remove studs - A - (upper illustration).
- Insert bolt - c -.
Tightening sequence:
- Tighten bolt - a - to 30 Nm.
- Tighten bolt - b - (lower illustration) to 25 Nm.
- Tighten bolt - c - to 25 Nm.
- Install pivot pin - arrow - for shift forks. To do this align shift mechanism using a screwdriver, so that the relevant pivot pin can be installed.
- Apply sealant (AMV 188 200 03) evenly onto the sealing surface of the sealing cover.
- Install sealing cover for selector shaft.
Install selector shaft with selector cover as follows:
- Move shift rails to neutral position.
- Apply sealant (AMV 188 200 03) evenly onto the sealing surface of the selector cover.
- Move shift shaft to neutral position.
- Position shift shaft so that shift finger - arrow - is inserted into the shift rails.
- Tighten selector shaft selector cover to specified torque --> [ (item 15) Multi-point socket head bolt, 25 Nm ] Transmission Housing and Shift Mechanism.
Installation position of gear-wheel for 5th gear
The circumferential groove - arrow - faces toward transmission housing.
- Drive on gear-wheel for 5th gear.
Checking 5th gear synchronizer ring
- Before reinstalling drive gear and synchronizer ring for 5th gear, press synchronizer ring onto taper of the drive gear and measure the gap dimension - a - using a feeler gauge.
- Install 5th gear drive gear with needle bearing.
- Place 5th gear synchronizer ring onto drive gear.
- If disassembled, assemble 5th gear synchronizer hub/locking collar before installing --> [ Assembling 5th gear locking collar/synchronizer hub ] Input Shaft.
Installation position of 5th gear synchronizer hub/locking collar
The pointed teeth of the locking collar - arrow 1 - and the high shoulder of the synchronizer hub - arrow 2 - face toward the transmission housing.
The notches - arrow 3 - of the synchronizer hub are aligned with the cast locking pieces of the synchronizer ring (--> [ 5th gear synchronizer ring with cast locking pieces ] lower).
5th gear synchronizer ring with cast locking pieces
- To prevent foreign bodies from entering the transmission, cover all openings with a rag.
• Make sure bracket (30- 211A) is installed.
- .Support input shaft using driving sleeve (32 - 111)
Otherwise, there is the danger input shaft bearing could be damaged when installing 5th gear synchronizer hub.
- Secure Bracket (30- 211A) bolt with nut - A -.
- Drive on synchronizer hub for 5th gear.
• When driving on, make sure synchronizer ring is free to move.
- Loosen input shaft support (Ill. N34-1810).
- Clean synchronizer hub and 5th gear drive gear threaded holes of locking compound residue with a thread tap.
Otherwise, there is the danger that the bolts could shear off.
- Screw-in synchronizer hub bolts and 5th gear wheel.
Installation position of plate springs for 5th gear synchronizer hub and gear-wheel securing bolts
The outer diameter - arrows - faces toward 5th gear.
- Tighten synchronizer hub and 5th gear drive gear bolts to specified torque.--> [ Cover for Transmission Housing and 5th Gear ] Cover for Transmission Housing and 5th Gear
- Tighten synchronizer hub and 5th gear drive gear bolts to specified torque - A - --> [ 4 Bolt, 80 Nm plus an additional 90° ] Cover for Transmission Housing and 5th Gear and insert 5th gear - arrow 1 - and 1st gear - arrow 2 - and - 3 -.
- After engaging both gears, the input shaft and output shaft are locked, synchronizer hub and gear-wheel cannot turn. Now both bolts can be tightened.
- Install 5th gear shift fork.
Adjusting 5th gear
- Engage 5th gear. Remove bolt - 1 -. Press locking collar and shift jaw in direction of - arrows -, then tighten 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. If necessary, repeat the adjustment.
- Disengage 5th gear. Locking collar must now be in the neutral position. Synchronizer ring must move freely.
- Shift through all gears.
- Install transmission housing cover.--> [ Cover for Transmission Housing and 5th Gear ] Cover for Transmission Housing and 5th Gear
- Install both flange shafts with springs, thrust washers and tapered rings.--> [ Input Shaft and Pinion Shafts, Differential and Shift Forks ] Input Shaft and Pinion Shafts, Differential and Shift Forks
- Install guide sleeve for release bearing --> [ Clutch Release Mechanism, Servicing ] Service and Repair.
- Install clutch release lever and release bearing --> [ Clutch Release Mechanism, Servicing ] Service and Repair.
- Filling up gear oil --> [ Observe the following assembly for ] Transmission, Installing