Part 2

Disassembling and assembling sequence, 02X, 6-Speed Four-Wheel Drive M/T Continued

Insert spring in selector gear
Heat gear wheels, needle bearing inner races and synchronizing hubs to 130° C (max.) before pressing on (wear protective gloves).
- Insert hollow shaft in bearing housing and selector fork for 1st and 2nd gear.





- Place reverse gear selector gear with needle bearing, spring and synchro-ring onto hollow shaft.

The tabs on synchro-ring should engage into recesses in selector gear.
- Press on reverse gear synchronizing hub.

Installation position: high inside collar faces 3rd gearwheel.
- Check axial clearance of reverse selector gear.





- Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an angle toward rear.
- Install reverse gear wheel and tighten 3 bolts for reverse shaft support to 30 Nm.





- Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod B - and reverse gear synchronizing hub.

The markings on locking collar and synchronizing hub - arrow - must coincide.

The chamfer on locking collar faces reverse selector gear.

If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.





- Align work surface of workshop press V.A.G 1290 A so that the 3rd hole - arrow - is visible above work surface.
- Place holding plate T40088/1 with sleeve T40088/2 onto work surface.
- Insert bearing housing with shafts and selector rods into holding plate T40088/1.

The distance between input shaft - 1 - and thrust disc VW 412 should be approx. 210 mm, so that it is possible to perform the following work steps without changing the position of the work surface.





- Press on 3rd gear wheel.

Installation position: machined side faces reverse gear synchronizing hub.
- Insert circlip for 3rd gear wheel.

When replacing gear wheel or hollow shaft:
Re-determine thickness of circlip for 3rd gear wheel:
- Determine thickest circlip that will just fit and install it.

The following circlips are available:








- Press on thrust washer - A - for 3rd speed selector gear until limit stop.





- Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto input shaft.
- Install 3rd speed selector gear with spring and synchro-ring.

The tabs on synchro-ring should engage into recesses in selector gear.





- Press on heated synchronizing hub for 3rd and 4th gear

Installation position: high inside collar faces 3rd speed selector gear.





- Insert circlip for synchronizing hub for 3rd and 4th gear.

When replacing synchronizing hub or input shaft:

Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:
- Determine thickest circlip that will just fit and install it.

The following circlips are available:





- Check axial clearance of 3rd speed selector gear.





- Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and synchronizing hub for 3rd and 4th gear.

The markings on locking collar and synchronizing hub - arrow - must coincide.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.

Note:
^ Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm) into selector fork for 3rd and 4th gear.





- Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd and 4th gear - B -.
- Press on heated inner race - C - for needle bearing for 5th speed selector gear.
- Check axial clearance of 4th speed selector gear.





- Heat 4th gear wheel and press on.

Installation position: high inside collar faces 5th gearwheel.





- Heat 5th gear wheel and press on.

Installation position: high inside collar faces 4th gear wheel.
- Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.

The lugs on synchro-ring should engage into recesses in selector gear.





- Install and press on heated synchronizing hub for 5th and 6th gear.
- Check axial clearance of 5th speed selector gear.





- Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for 5th and 6th gear.

The markings on locking collar and synchronizing hub - arrow - must coincide.
- Move selector fork for 5th and 6th gear - C - into selector rod - B -.
- If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.





- Press on heated inner race for needle bearing for 5th speed selector gear.





- Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A -.
- Heat inner race - B - for needle roller bearing and press on.
- Check axial clearance of 6th speed selector gear.





- Install spacer sleeve - A - onto hollow shaft.
- Heat 6th gear wheel and press on.





Insert circlip - A - for 6th gear wheel.

When replacing gear wheel or hollow shaft:

Re-determine circlip - A - for 6th gear wheel:
- Determine thickest circlip that will just fit and install it.

The following circlips are available:





- Remove bearing housing from holding plate T40088/1.





- Push pinion shaft - B - with large needle bearing into hollow shaft - C - and fit small needle bearing - A -.
- Prevent pinion shaft from falling out and secure on hollow shaft using e.g. a hose clip.





- Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows - and washers.
- Tighten two bolts to max. 10 Nm.

Note:
^ Do not install oil collector - A - at this stage.





- Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).





- Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
- Remove complete bearing housing from transmission housing.
- Check that the two dowel sleeves for centralizing bearing housing are installed in transmission housing.
- Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between transmission housing and bearing housing.
- Install bearing housing onto transmission housing.





- Clip oil collector - A - into reverse shaft support.

Note:
^ Make sure that the bolts - arrows - are removed.

- Remove hose clip from pinion shaft.
- Check that the two dowel sleeves for centralizing the transmission cover are installed in bearing housing.
- Apply sealing paste AMV 188 001 02 evenly and not too thick onto contact surfaces between bearing housing and transmission cover.





- Tighten securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C - to 35 Nm plus an additional 90° 1/4 turn.
- Lubricate new O-ring - arrow - with gear oil.





- Place spring - 2 - and Torsen differential - 3 - onto pinion shaft/hollow shaft - 1 -.
- Install Torsen housing - 5 - onto transmission cover.
- Tighten bolts - 4 - to 10 Nm plus an additional 45° 1/8.





- Push assembly sleeve 01E311120 - A - onto selector shaft - B -.

Note:
^ Avoid damaging oil seal - C - by only installing oil seal and selector shaft using assembly sleeve assembly sleeve 01E311120 - A -.

- Move selector rods to neutral.
- Install complete selector shaft.

Installation position: Chamfer of selector shaft points downward.





- Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.

Installation position for pin - 3 -: The groove - arrow - on pin points toward selector shaft cover.
- Clean bolt threads of locking fluid - 1 - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 45 Nm.





- Install cover - A - with new O-ring.
- Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 24 Nm.





- Install rear circlip - arrow - for input shaft ball bearing.
- Push ball bearing onto input shaft.

Installation position:
The sealed side of ball cage faces transmission housing.





- Pressing in ball bearing:

Screw replacement stud (M8 and M10) 3114/2 into tapped hole for ball head stud

Slide thrust plate - A - of fitting tool T10246 onto input shaft.

Position fitting tool T10246 behind splines for clutch plate. Tighten bolts - B - lightly. The bolts locate in the recess in thrust plate - A -.

Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).





- Install front circlip - D - for input shaft ball bearing.
- Install dished spring - C -.

Installation position:
The curved side faces guide sleeve - B -.
- Install a shrink hose onto input shaft splines.
- Install guide sleeve - B - for release bearing.
- Remove shrink hose.
- Install clutch release lever - A - with release bearing.
- Select all gears.