Input & Pinion Shaft, Selector, Cover: Disassemble/Assemble

Input Shaft Ball Bearing, Multi-Function Switch, Input Shaft, Pinion Shaft, Shift Rods and Transmission Cover, Removing and Installing

Notes:

- To remove the above-mentioned components, it is not necessary to remove the differential.
- Removal is only necessary when adjustments have to be performed. List of Adjustments

Special tools and equipment

- VW309 holding plate
- VW353 transmission support
- 3235 press device
- VAG1306 drip tray
- VAG1582 taper roller bearing puller
- VAG1582/2 gripping piece
- AMV 188 001 02 sealant

Removing

- Place VAG1306 drip tray under transmission.
- Drain transmission oil.
- Secure transmission to assembly stand. Securing Transmission to Assembly Stand






- Remove clutch release lever -A- with release bearing.

Notes:

- Before removing the guide sleeve, slide a shrink tube over the input shaft splines to protect the seal.
- Remove the seal in the guide sleeve, Clutch Release Mechanism, Servicing

- Remove guide sleeve -B-.
- Remove spring 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.






- Remove transmission cover -A- from transmission housing -B-.






- Remove bolts (arrows) and pull out multifunction switch.






- Remove relay shaft bolts (arrows).






- Unbolt shift detent (arrow) and swing out.






- Input shaft -A-, pinion shaft -B-,relay shaft -C-, selector rods -D- with shift rod and shift forks -E- must all be carefully pulled out together.

Installing

Note:

- If the input shaft ball bearing, the input shaft or the transmission housing is replaced, it is necessary to re-determine the thickness of the circlips for the input shaft first. Input Shaft, Adjusting






- For easier installation of following components, swing transmission housing into position shown.






- Assemble input shaft -A-, pinion shaft -B-,relay shaft -C-, selector rods -D- with shift rod and selector forks -E-.
- Install these components into transmission housing as a set.

Note:

- The relay shaft -C- and the shift rod can also be installed later if necessary.






- Position of shift mechanism in transmission
1. Shift fork 5th and reverse gears
2. Shift fork 3rd and 4th gears
3. Shift fork 1st and 2nd gears
4. Relay shaft
5. Shift detent
6. Shift rod

Note:

- Illustration is shown without the drive axle and pinion.






- Move transmission housing and engage 3rd gear (direction of arrow).






- Install relay shaft -A-.
- Place inner shift rod -B- sideways into mounting hole in transmission housing and assemble into mounting eye.
- Carefully turn shift rod in direction shown (arrow).






- Insert shift detent and tighten bolt (arrow) securely.






- Install relay shaft stop bolts (arrows).
- Replace O-ring for multi-function switch.






- Carefully insert multi-function switch and tighten (arrows).






Make sure dowel sleeves for transmission cover are installed in transmission housing -B-.
- Coat sealing surfaces with a thin layer of sealant AMV 188 001 02.
- Install transmission cover onto transmission housing.






- Install rear circlip (arrow) for input shaft ball bearing.
- Slide ball bearing onto input shaft.
- Installation position: closed side of ball cage faces toward transmission housing.






- Press in ball bearing.
- Slide thrust piece -A- of press device onto input shaft.
- Position press device behind splines for clutch plate.
- Screw in bolts -B- and tighten slightly.
- The bolts bear against the indentations in thrust piece -A-.
- Press in ball bearing onto seat by alternately tightening bolts -B- (1/2-turn at a time) until stop is reached.






- Install front circlip -D- for input shaft ball bearing.
- Install spring washer -C-.
- Position: convex side faces guide sleeve -B-.

Notes:

- Before installing guide sleeve, cover splines on input shaft with a shrink tubing to protect the seal.

- Installing seal in guide sleeve. Clutch Release Mechanism, Servicing






- Install guide sleeve -B- for throwout bearing.
- Install clutch release lever -A- and throwout bearing.