Transmission, Assembling
Transmission, Assembling
If the input shaft or the transmission housing are being replaced, first determine the thickness of the input shaft circlip. Refer to => [ Input Shaft, Adjusting ] 02XA Transmission.
• Coat all the needle bearings with transmission oil before installing.
• Checking synchronizer rings for wear. Refer to => [ Checking Synchronizer Ring for Wear ] Input Shaft
• Inserting spring into selector gear. Refer to => [ Inserting Spring into Selector Gear ] Input Shaft
• Before pressing off the gears, the needle bearing inner races and the synchronizer hubs, warm them to maximum 130 °C wearing protective gloves.
- Install the hollow shaft into the bearing housing and into the 1st and 2nd gear shift fork.
- Mount the reverse gear wheel with needle bearing, the spring and synchronizer ring on the hollow shaft.
• Lugs of synchronizer ring engage into notches of selector gear lying below.
- Pressing on synchronizer hub for reverse gear.
• Installation position: High inner collar faces 3rd gear drive gear
- Check the axial play on the reverse gear wheel.
- Install the input shaft - A - and roller sleeve - B - in direction of - arrow - at an angle to the rear into the bearing housing.
- Install the reverse gear and tighten the 3 bolts for the support/reverse shaft to 30 Nm.
- Slide the reverse gear shift fork - C - together with the locking collar - D - over the shift rod - B - and the reverse gear synchronizer hub.
• The marking on the locking collar and the synchronizer hub - arrow - must align.
• The cone in the locking collar faces the reverse gear wheel.
- When the holes in the shift fork and shift rod align, install the dowel pin and clamp - A -.
- Align the press table from the Workshop Press ( V.A.G 1290 A) so that the 3rd hole - arrow - is visible above the table.
- Place the Plate (T40088/1) and the Sleeve (T40088/2) on the press table.
- Install the bearing housing with the shafts and shift rods into the Plate (T40088/1).
The distance between the input shaft - 1 - and the Thrust Disc (VW 412) must be approximately 210 mm so that it is not necessary to change the position of the press table for other procedures.
- Install the 3rd gear.
• Installation position: the sanded side face the reverse gear synchronizer hub
- Install the 3rd gear circlip.
• When replacing the gear wheel or hollow shaft:
Redetermine circlip for 4th gear drive gear:
- Determine thickest circlip which can still just be installed and insert it.
The following circlips are available:
- Install the thrust washer - A - all the way onto the 3rd gear wheel.
- Mount the 3rd gear needle bearing - 1 - and the circlip - 2 - on the input shaft.
- Mount the 3rd gear wheel with spring and synchronizer ring.
• Lugs of synchronizer ring engage into notches of selector gear lying below.
- Install the warmed-up 3rd and 4th gear synchronizer hub.
• Installation position: high inner collar faces 3rd gear wheel
- Install the circlip for 1st and 2nd gear synchronizer hub
• When replacing the synchronizer hub or input shaft:
Determine the circlip for the 3rd and 4th gear synchronizer hub:
- Determine thickest circlip which can still just be installed and insert it.
The following circlips are available:
- Check the 3rd gear wheel for axial play.
- Slide the 3rd and 4th gear shift fork - C - together with the locking collar - D - over the selector rod - B - and the 3rd and 4th gear synchronizer hub.
• The marking on the locking collar and the synchronizer hub - arrow - must align.
- When the holes in the shift fork and shift rod align, install the dowel pin and clamp - A -.
• Install the dowel pin and clamp for the 5th and 6th gear shift fork dia. 6 mm but not into the 3rd and 4th gear shift fork.
- Mount the 4th gear wheel - A - and spring, the synchronizer ring, needle bearing and thrust washer for 3rd and 4th gears - B -.
- Install the warmed-up inner race - C - for the 5th gear needle bearing.
- Check the 4th gear axial play.
- Warm up the 4th gear and install.
• Installation position: High inner collar faces the 5th gear.
- Warm up the 5th gear and install.
• Installation position: High inner collar faces 4th gear.
- Mount the 5th gear with spring, synchronizer ring and needle bearing on the input shaft.
• Lugs of synchronizer ring engage into notches of selector gear lying below.
- Warm up the synchronizer hub for 5th and 6th gear and install.
- Check the 5th gear wheel axial play.
- Slide the 5th and 6th gear shift fork - C - together with the locking collar - D - over the 5th and 6th gear synchronizer hub.
• The marking on the locking collar and the synchronizer hub - arrow - must align.
- Move the 5th and 6th gear shift fork - C - into the selector rod - B -.
- When the holes in the shift fork and shift rod align, install the dowel pin and clamp - A -.
- Install the warmed-up inner race for the 5th gear needle bearing.
- Mount the 6th gear wheel with spring, synchronizer ring, needle bearing and thrust washer - A -.
- Warm up the inner race - B - for the roller sleeve and install it.
- Check 6th gear selector gear for axial play.
- Install the spacer sleeve - A - on the hollow shaft.
- Warm up the 6th gear and install.
Install the circlip - A - for the 6th gear wheel.
• When replacing the gear wheel or hollow shaft:
Determine the circlip - A - for 6th gear wheel:
- Determine thickest circlip which can still just be installed and insert it.
The following circlips are available:
- Remove the bearing housing from the Plate (T40088/1 ).
- Slide the pinion - B - with the large needle bearing into the hollow shaft - C - and install the small needle bearing - A -.
- Secure the pinion from falling out, for example, with a hose clamp => [ Secure the pinion from falling out, for
example, with a hose clamp. ] Transmission, Assembly Sequence.
- Secure the bearing housing to the transmission housing with two M8, 70 mm bolts - arrows - and washers.
- Tighten both bolts to maximum 10 Nm.
• Do not install the oil collector tray - A - yet.
- Secure the input shaft by engaging 2 gears, for example, reverse and 1st gear, by moving 2 selector rods - arrow A - and - arrow B -.
- Tighten the internal multi-point bolt - 1 - for the input shaft to 150 Nm.
- Remove the bearing housing from the transmission housing.
- Make sure there are 2 alignment sleeves inside the transmission housing for the bearing housing.
- Apply Sealing Paste (AMV 188 001 02) evenly and not to thick on the transmission housing joint surfaces at the bearing housing.
- Attach the bearing housing to the transmission housing.
- Install the oil collector tray - A - into the support/reverse shaft.
• The bolts - arrows - must be removed.
- Remove the hose clamp from the pinion => [ Secure the pinion from falling out, for
example, with a hose clamp. ] Transmission, Assembly Sequence.
- Make sure there are 2 alignment sleeves inside the bearing housing for the transmission cover.
- Apply Sealing Paste (AMV 188 001 02) evenly and not to thick on the bearing housing joint surfaces at transmission cover.
- Tighten the transmission cover bolts - A - and bearing housing - B - to the transmission housing - C - to 35 Nm + 90° turn.
- Install the new O-ring - arrow - and coat it with transmission oil.
- Position the small pressure spring - 2 - and center differential - 3 - on the pinion/hollow shaft - 1 -.
- Install the large pressure spring - 4 -.
- Position the center differential housing - 5 - on the transmission cover.
- Tighten the bolts - arrows -. Tightening specification => [ (Item 2) Bolt, 10 Nm plus an additional 45° turn ] Self-Locking Center Differential Assembly Overview.
• Only 4 of the 6 bolts are shown in the illustration.
- Push Assembly Sleeve (01E 311 120) - A - onto selector shaft - B -.
• To prevent damage to the seal - C -, the installation of the seal and selector shaft must only be performed with the Assembly Sleeve (01E 311 120) - A -.
- Bring the selector rods in idle position.
- Install complete selector shaft.
• Installation position: Flattened part of selector shaft faces downward.
- Slide the selector shaft - 2 - into transmission all the way and install the dowel pin - 3 -.
• Dowel pin installation location - 3 -: The groove - arrow - in the dowel pin face the selector shaft cover.
- Clean locking bolt threads - 1 - with a wire brush. Then insert bolts with Locking Compound (AMV 185 101 A1 ) and tighten to 45 Nm.
- Install the cover - A - with an O-ring.
- Clean bolt threads - arrows - with a wire brush. Then insert bolts with Locking Compound (AMV 185 101 A1 ) and tighten to 24 Nm.
- Install the rear circlip - arrow - for input shaft ball bearing.
- Then slide ball bearing onto input shaft.
Installation position:
Closed side of cage for balls points toward transmission housing.
- Install the ball bearing:
First install the M8 and M10 Replacement Stud ( 3114/2) into the threaded hole for the ball stud.
Slide thrust pad - A - of Press Device (T10246) onto input shaft.
Now place Press Device behind clutch plate splines. Pre-tension bolts - B -. The bolts bear against the indentations in thrust piece - A -.
Press in ball bearing onto seat by alternately tightening bolts (1/2 turn at a time) until stop is reached.
- Install front circlip - D - for input shaft ball bearing.
- Then install plate spring - C -.
Installation position:
Convex side faces guide sleeve - B -.
- Place a heat-shrinkable tube on the input shaft spline.
- Install the guide sleeve - B - for the release bearing.
- Remove the heat-shrinkable tube.
- Install the clutch release lever - A - with release bearing.
- Shift through all gears.