Transmission, Assembly Sequence

Transmission, Assembly Sequence

Center Differential Housing, Center Differential, Side Shaft, Transmission Cover, Input and Output Shafts Together with Transmission-Side Shift Mechanism, Removing and Installing

• You do not need to remove the differential when removing the components listed above.

• Refer to general repair instructions. Refer to => [ General Repair Information ] General Repair Information.

Special tools, testers and auxiliary items required

• Driving Sleeve (VW 244 B)

• Thrust Piece (40 -105)

• Socket , Multi Point Bit XZN 14 (T10061)

• Pulling Hook (T20143)

• Thrust Piece (T40166)

• Extractor (T40176)

• Driver (3013)

• Gearbox Support (T40206)

• Assembly Tool (T40213)

• Support Tool (T40214)

• Guide Pin (T40216)

• Counterhold Tool (T40217)

• Clamping Sleeve (3116)

• Counterhold Tool (T40215)

• Thread Locking Compound (AMV 185 101 A1)

• Sealing Paste (AMV 188 001 02)

• Grease for Clutch Disc Shaft Splines (G 000 100)

• Adhesive Lubricating Paste (G 000 150)

• Sealing Grease (G 052 128 A1)

Transmission, disassembling

- Place drip tray underneath.

- Remove the bolt - arrow - and drain the transmission oil.

- Secure the transmission holder (T40206) to the transmission with the bolts - arrows - and tighten it in the assembly stand.

- Remove the clutch module. Refer to => [ Clutch Module ] Clutch Module.

- Set the clutch module down carefully, for example on the workbench.

- Remove the clutch release lever - 1 - together with the release bearing - 2 - and the spring - 3 -.

- Remove the bolts - 4 -, the locking plate - 5 - (if equipped) and the guide sleeve - 6 -.

- Pry out the input shaft seal.

- Circlip - arrow - in front of the ball bearing of input shaft must then be removed.

• If it is not possible to remove the locking ring, then remove the transmission cover first and then move the input shaft forward using a rubber hammer.

- Push the cover - A - for the output shaft in the center and pry it out in direction of - arrow -.

- Remove the bolts - A -, - B - and - arrows - that attach the center differential housing - C - to the transmission cover.

• Not all versions have the double bolts - B -; allocation, refer to the electronic parts catalog ETKA.

- Carefully remove the center differential housing - 6 -, the pressure spring - 3 -, the adjusting shim - 4 - and the plate spring - 5 -.

- Remove the center differential - 2 - and the gear carrier - 1 -.

If the gear carrier - 1 - remains in the center differential housing, proceed as follows:

- Grip the side ridge on the gear carrier - 1 - using a pair of pliers and remove it in direction of - arrow A -.

- Using a rubber hammer, tap the housing on alternating sides - B arrows -.

Do not damage sealing surfaces when doing so.

Loosen the twelve-point bolt - A - for the side shaft - B - on the pinion as follows:

- Mount a twelve-point socket - C - (21 mm) with an extension - D - over the twelve-point bolt - A -.

- Insert the (T40217) with the outer splines - arrow 1 - into the inner splines - arrow 2 - on the side shaft.

- Secure the (T40217) to the transmission cover with the M8 bolt - arrows -.

- Remove the side shaft twelve-point bolt on the pinion.

- A - torque wrench

- Mount the (T40215) all the way onto the spur gear - A - for the side shaft and on the output shaft - B -.

• The (T40217) remains attached to the transmission cover.

• The output shaft will be blocked after the special tool is installed and will not turn.

- Loosen the bolt - A - on the output shaft using the (T10061).

• The bolt - A - has a very high loosening torque (approximately 300 to 350 Nm).

B Torque Wrench

- Remove the (T40215) and (T40217).

- Remove the side shaft - 1 - from the transmission cover.

- Remove the spur gear - 2 - for the spur gear and the needle bearing from the output shaft - 3 -.

- If equipped, remove the transmission neutral position sensor (G701) - A -.

- Remove the bolt - arrow - and remove the sensor from the cover - B -.

• The cover - B - remains installed.

• It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor.

- Remove the bolts - 1 - and pry the selector shaft cover - 2 - off carefully.

- Raise the selector shaft slightly - arrow A - and remove it - arrow B -.

- Then turn transmission in assembly bracket so transmission cover - C - faces up.

- Remove the bolts - A - (for the bearing bracket) and the bolts - B - that attach the transmission cover - C - to the transmission housing - D -.

• Make sure the bolt - arrow - is a 50 mm steel bolt when installing the transmission cover.

- Remove the transmission cover - C -.

- Remove the oil catch tray - 1 - from the gearshift rail / shift fork for 3rd and 4th gears - 2 - and from the bearing bracket - 3 - - arrows A through D -.

- Attach the (T40213) to the (T40206) using the bolts - arrows -.

There is a danger of causing damage to the toothed gears, the shafts and bearings.

• The input and output shafts must be removed together.

• It is permissible to remove the shaft alternating from side to side by turning each spindle maximum one turn.

- Remove the input and output shafts from the ball bearings inside the transmission housing by turning the spindles on the (T40213) one turn and alternating from side to side.

- At the same time, remove the reverse shaft support - 2 - from the transmission housing - arrow B -.

- Remove the reverse drive gear - 1 - and the reverse shaft support - 2 - from the drive axle.

- Remove the input shaft - 1 - and the output shaft - 2 - together with the shift fork group - 3 - from the transmission housing.

- Remove the oil catch tray - 4 - and the magnet - 5 -.

Transmission, assembling.

• The adjusting shim for the bearing tension on the spur gear tapered roller bearing must be determined again whenever replacing the transmission cover, the spur gear, the spur gear tapered roller bearing, the gear carrier or the center differential housing. Refer to => [ Spur Gear Tapered Roller Bearing Pre-Load, Determining ] Spur Gear Tapered Roller Bearing Pre-Load, Determining.

• The reverse drive gear and the reverse shaft support must be installed before the input and output shafts touch the bearing seat in the ball bearing.

- Install the oil catch tray - 4 - and the magnet - 5 - into the transmission housing.

- Install the input shaft - 1 - and the output shaft - 2 - together with the shift fork group - 3 - into the transmission housing.

- Install the reverse drive gear - 1 - and the reverse shaft support - 2 -. When doing this, insert the tab - arrow A - into the opening - arrow B - in the transmission housing.

- Attach the support tools (T40214/1) and (T40214/2) to the transmission housing using the bolt - 1 - and - 2 -, as illustrated.

- Attach the plate (T40213/1) to the support tools (T40214/1 and T40214/2).

- Mount the (3116) and on the output shaft and the (40-105) on the input shaft.

There is a danger of causing damage to the toothed gears, the shafts and bearings.

• The input and output shafts must be installed together.

• It is permissible to install the shaft alternating from side to side by turning each spindle maximum one turn.

- Then install the input and output shafts all the way into the ball bearing by turning the spindles (T40213/2) one turn alternating from side to side.

- Remove the (T40213) and the (T40214).

- Install the oil catch tray - 1 - with the tab - arrow A - into the hole - arrow B - in the bearing bracket - 3 - and then install the bearing bracket - arrow C - and the gearshift rail / shift fork for 3rd and 4th gears - 2 - - arrow D -.

- Make sure the 2 alignment bushings for centering the transmission cover / transmission housing are inside the transmission housing.

- Apply sealing paste (AMV 188 001 02) evenly and not to thick on transmission housing joint surfaces at transmission cover.

- Mount the transmission cover - C - on the transmission housing - D -.

- Clean bolt threads - A - with a wire brush. Install the bolts with locking fluid (AMV 185 101 A1) and install them hand-tight into the bearing bracket.

- Tighten the new aluminum bolts (quantity: 16; 35 mm long) - B - to the tightening specification.

- Tighten the steel bolt - arrow - (50 mm long) under the hole for the clutch slave cylinder to the tightening specification.

- Then tighten the bolts - A - to the tightening specification.

Determine the Locking Ring - arrow - for the Input Shaft as Follows:

- Determine thickest circlip which can still just be installed and insert it. For the part number, refer to the electronic parts catalog ETKA

• Begin with the thickest locking ring.

The following locking rings are available:

- Mount the spur gear - 2 - and the needle bearing - 21 - => [ Needle Bearing ] Left Flange Shaft, Clutch Module, Side Shaft, Gearshift Shaft and Transmission Cover Assembly Overview on the output shaft - 3 -.

• The adjusting shim for positioning the center differential must be determined again when the transmission cover, the spur gear, the spur gear tapered roller bearing or the spacer sleeve are replaced. Refer to => [ Adjusting Shim S for Positioning Center Differential, Determining ] Adjusting Shim S6 For Positioning Center Differential, Determining.

- Install the side shaft - 1 - all the way into the transmission cover.

Tighten the twelve-point bolt - A - for the side shaft - B - on the pinion as follows:

- Tighten the side shaft twelve-point bolt to the pinion to the tightening specification.

- A - torque wrench

- Mount the (T40215) all the way onto the spur gear - A - for the side shaft and on the output shaft - B -.

• The (T40217) remains attached to the transmission cover.

• The output shaft will be blocked after the special tool is attached and will not turn.

- Clean the threads on the bolt - A - on the output shaft with a wire brush. Then install and tighten the bolts with locking fluid (AMV 185 101 A1) to the tightening specification.

B Torque Wrench

- Remove the (T40215) and (T40217).

- Lightly coat the cover - A - for the output shaft with oil on the outer circumference and then install it.

- Lightly oil outer circumference of new shaft seal for the input shaft.

- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).

- Drive the new seal in until it is flush without tilting it.

Install the gear carrier on the transmission cover as follows:

• Installed position: the tab - arrow A - on the gear carrier - 2 - must installed into the opening - arrow B - inside the transmission cover.

- Install the oil catch tray - 1 -.

- Mount the spacer sleeve - 3 - and the adjusting shim - 4 - (for positioning the center differential) on the output shaft.

- Slide the center differential - 2 - all the way in direction of the gear carrier - 1 -.

- Insert the plate spring - 5 -, the adjustment shim(s) - 4 - and the spring - 3 - in the center differential housing - 6 -.

• Plate spring installed position - 5 -: the inner diameter with it camber - arrow - faces the center differential housing - 6 -.

- Apply sealing paste (AMV 188 001 02) evenly and not too thick.

- Then position the center differential housing - 6 - on the transmission.

- Press the center differential housing - C - on until it makes contact with the transmission cover and hold it securely.

- Install the new bolts - A -, - B - and - arrows - and tighten them to the tightening specification.

• Not all versions have the double bolts - B -; allocation, refer to the electronic parts catalog ETKA. Bolts are installed in place of the double bolts - 2 - => [ Bolt ] 0B2A Manual Transmission.

- Install the new O-ring on the cover - 2 -.

- Install the (T40216) on the selector shaft - 1 -.

- Insert the selector shaft in the transmission - arrow A - by raising it slightly - arrow B -.

- Bring the selector shaft cover - 2 - into contact with the transmission housing.

- Tighten the new bolts - 1 - to the tightening specification.

- Remove (T40216).

- If equipped, install the transmission neutral position sensor (G701) - A - with a new O-ring in the gearshift shaft cover - B -.

- Tighten new bolt - 1 - to the tightening specification.

- Install the guide sleeve - 6 - and the locking plate - 5 -, if equipped.

- Clean bolt threads - 4 - with a wire brush. Then install and tighten the bolts with locking fluid (AMV 185 101 A1) to the tightening specification - 6 - => [ Bolt ] Clutch Release Mechanism Assembly Overview.

Noises when actuating the clutch

• Rattling noises can occur when pressing the clutch if there is not enough grease on the release bearings.

• Lubricate the release bearings with adhesive lubricating paste (G 000 150). Refer to => [ Clutch Release Mechanism Assembly Overview ] Clutch Release Mechanism Assembly Overview.

• Remove any grease still in the guide sleeve bearing area.

- Install the clutch release lever - 1 - together with the release bearing - 2 - and the spring - 3 -. Refer to => [ Clutch Release Mechanism Assembly Overview ] Clutch Release Mechanism Assembly Overview.

Check which version of the needle bearing is inside the dual mass flywheel.

• Needle bearings is missing the 4th roller - arrows - must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to => [ Dual Mass Flywheel Needle Bearing, Sachs and LuK ] Dual Mass Flywheel Needle Bearing, Sachs and LuK.

• New needle bearings are equipped with rollers.

• On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!

- Install the clutch module and the left flange shaft => [ Install the Clutch Module ] Clutch Module.

- Fill the transmission with transmission fluid and check the level. Remove the oil filler plug - arrow -.