Disassembling and Assembling Transmission
Disassembling and assembling transmission
Caution
High pressing forces can occur when pressing the components off the output shaft. To avoid injury as a result of splinters and chips, for example, the press-off tool must be fitted with a splinter shield (e.g. plastic shield).
Information
^ A press that can apply a press-off force of at least 250 kN is required for carrying out the work described here.
^ When replacing a loose gear wheel, the related fixed gear wheel must also be replaced if the transmission mileage is more than 20,000 km (12,000 miles).
^ If fixed gear wheels were removed, an R must be stamped in front of the transmission number when the transmission is assembled again.
^ If more than one R is already stamped, the fixed gear wheels can no longer be fitted, removed or replaced. The transmission must be replaced in this case.
Tools and materials
Tool overview
Information
^ Unless expressly specified otherwise, the knurled side of the tool must be facing the press tool.
^ The spacer VW 545/2 must be used between the press tool and shaft for all pressing work on the output shaft.
Removing transmission cover
Information
^ The cardan shaft flange must be removed on all-wheel-drive vehicles before removing the transmission cover.
1. Remove transmission.
2. Use engine support 9589 to secure the transmission on the assembly support.
3. Change transmission oil.
4. Remove switch interlock. To do this, unscrew the hexagon socket head bolt -A- and remove the compression spring -B- and locking pin -C-.
Removing switch interlock
5. Unscrew fastening screws for front transmission cover and force transmission cover off with a rubber hammer if necessary.
Information
^ When removing the transmission cover, make sure to leave the shift segment roller in place.
Removing gear wheel set
Overview
Overview
Removing gear wheel set
1. Remove magnet (no. 6 in overview) from the transmission housing (no. 25 in overview).
2. Remove four shift control lock devices (nos. 7 to 9 in overview).
3. Engage reverse gear.
4. Drive out mounting cotter pin (no. 10 in overview) between the shift rod for reverse gear and the shift fork for reverse gear (no. 11 in overview). Pull shift rod out of the transmission housing and remove shift rod with shift fork.
5. Drive out mounting cotter pin (no. 10 in overview) between the shift rod for 1st/2nd gear and the shift fork for 1st/2nd gear (no. 12 in overview). Pull shift rod out of the transmission housing and remove shift rod with shift fork.
6. Remove shifting shaft (no. 13 in overview) together with four rollers (no. 14 in overview).
7. Drive out mounting cotter pin (no. 10 in overview) between the shift rod for 3rd/4th gear and the shift fork for 3rd/4th gear (no. 15 in overview).
8. Drive out mounting cotter pin (no. 10 in overview) between the shift rod for 5th/6th gear and the shift fork for 5th/6th gear (no. 16 in overview).
9. Drive out mounting cotter pin (no. 10 in overview) between the shift rod for 3rd/4th gear and the shift finger guide (no. 17 in overview).
10. Pull shift rods for 3rd/4th gear and 5th/6th gear together with shift forks out of the transmission housing and remove them.
11. Unscrew fastening screws (no. 18 in overview) for halfshaft flange and remove halfshaft flange (no. 19 in overview).
12. Unscrew fastening screws (no. 20 in overview) and tap off side transmission cover (no. 21 in overview) using a rubber hammer if necessary.
13. Remove differential (no. 22 in overview).
14. Unscrew fastening screws on the tensioning plate (no. 23 in overview).
15. Heat up transmission housing for about 5 minutes using a hot-air gun and pull gear wheel set (no. 24 in overview) out of the transmission housing (no. 25 in overview).
Information
^ Make sure not to leave the outer bearing rings of the angular-contact ball bearings in the transmission housing because otherwise the sealing lips can be damaged irreparably.
^ The thickness of the adjusting shims (nos. 26 and 27 in overview) must not be changed.
Removing loose gear wheels on output shaft
Overview
Overview
Removing loose gear wheels on output shaft
Caution
High pressing forces can occur when pressing the components off the output shaft. To avoid injury as a result of splinters and chips, for example, the press-off tool must be fitted with a splinter shield (e.g. plastic shield).
Information
^ If there is not enough overlap between the output shaft and press tool on two-wheel-drive vehicles, a suitable press tool, e.g. adapter VW 295 A must be inserted into the output shaft.
1. Remove circlip (no. 1 in overview) and washer (no. 2 in overview) from the output shaft.
2. Insert gear wheel set with loose gear wheel for 2nd gear into the large bore on the assembly aid 9692.
Gear wheel set with loose gear wheel
3. Press off entire loose gear wheel set (nos. 3 to 28 in overview).
4. Remove needle-roller bearing (no. 29 in overview) from the output shaft.
Removing loose gear wheels on drive shaft
Overview
Overview
Removing loose gear wheels on drive shaft
Caution
High pressing forces can occur when pressing the components off the output shaft. To avoid injury as a result of splinters and chips, for example, the press-off tool must be fitted with a splinter shield (e.g. plastic shield).
1. Remove circlip (no. 1 in overview) and washer (no. 2 in overview) from the drive shaft.
2. Insert gear wheel set with loose gear wheel for 5th gear into the small bore on the assembly aid 9692.
Gear wheel set with loose gear wheel
3. Press out drive shaft (no. 30 in overview) through the entire loose gear wheel set (nos. 3 to 28 in overview).
4. Remove needle-roller bearing (no. 29 in overview) from the drive shaft (no. 30 in overview).
Removing fixed gear wheels on output shaft
Overview
Overview
Removing fixed gear wheels on output shaft
Warning
Preloaded or pressurized components
^ Risk of eye injuries
^ Risk of bruising
-> Wear personal protective gear.
-> Secure components to prevent them from falling off suddenly.
1. Insert fixed gear wheel for 5th gear (no. 2 in overview) into the small bore on the assembly aid 9692 and press off together with the inner bearing ring (no. 1 in overview).
Fixed gear wheel, 5th gear
2. Insert fixed gear wheel for 3rd gear (no. 4 in overview) into the large bore on the assembly aid 9692 and press off together with the fixed gear wheel for 6th gear (no. 3 in overview).
Fixed gear wheel, 3rd gear
3. Insert tensioning plate (no. 6 in overview) into the large bore on the assembly aid 9692 and press off together with the fixed gear wheel for 4th gear (no. 5 in overview).
Tensioning plate
4. Remove adjusting shims (nos. 7 and 8 in overview) from the output shaft (no. 10 in overview).
Information
^ Always replace angular-contact ball bearing after removing the output shaft.
5. Press angular-contact ball bearing (no. 9 in overview) off the output shaft (no. 10 in overview) with the separating device.
Angular-contact ball bearing
Fitting fixed gear wheels on output shaft
Overview
Information
^ Add other pipes to the prescribed pressure pieces as required on all-wheel-drive vehicles.
Fitting fixed gear wheels on output shaft
Caution
High pressing forces occur when pressing components onto the output shaft. To avoid injury as a result of splinters and chips, for example, the press-off tool must be fitted with a splinter shield (e.g. plastic shield).
Information
^ The output shaft, inner bearing rings and fixed gear wheels must be completely free of oil and grease before being fitted.
1. Press angular-contact ball bearing onto the output shaft using pressure plate VW 401 and tube VW 415 A. The turned groove is facing the bevel gear.
Pressing angular-contact ball bearing onto the output shaft
Information
^ The thickness of the adjusting shims (nos. 7 and 8 in overview) must not be changed.
2. Place adjusting shims (nos. 7 and 8 in overview) and tensioning plate (no. 6 in overview) on the angular-contact ball bearing of the output shaft (no. 9 in overview).
3. Heat fixed gear wheel for 4th gear (no. 5 in overview) to approx. 150 °C and press it onto the output shaft using special tool pressure piece 9694/4.
Pressing fixed wheel for 4th gear onto the output shaft
4. Heat fixed gear wheel for 3rd gear (no. 4 in overview) to approx. 150 °C and press it onto the output shaft using special tool pressure piece 9694/4.
Pressing fixed gear wheel for 3rd gear onto the output shaft
5. Heat fixed gear wheel for 6th gear (no. 3 in overview) to approx. 150 °C and press it onto the output shaft using special tool pressure piece 9694/4.
Pressing fixed gear wheel for 6th gear onto the output shaft
6. Heat fixed gear wheel for 5th gear (no. 2 in overview) to approx. 150 °C and press it onto the output shaft using special tool press-on sleeve 9694/3.
Pressing fixed gear wheel for 5th gear onto the output shaft
7. Heat inner bearing ring (no. 1 in overview) to approx. 150 °C and press it onto the output shaft using special tool press-on sleeve 9694/3 if necessary.
Fitting gear wheel set on drive shaft
Overview
Fitting loose gear wheels on drive shaft
Warning
Preloaded or pressurized components
^ Risk of eye injuries
^ Risk of bruising
-> Wear personal protective gear.
-> Secure components to prevent them from falling off suddenly.
Information
^ The guide sleeves and inner bearing rings must be completely free of oil and grease before being fitted.
^ All components that turn and the synchronization parts must be lubricated with transmission oil before assembly.
1. Check synchronizer rings for 5th/6th gear for wear. To do this, press the synchronizer rings onto the gear wheels and measure the gap -A- with a feeler gauge.
Synchronizer rings for 5th/6th gear
The gap dimension A must be between 1.0 and 1.8 mm.
2. Push needle-roller bearing (no. 30 in overview), loose gear wheel for 5th gear (no. 29 in overview) and spacer (no. 28 in overview) onto the drive shaft at the correct position.
3. Assemble synchronization (nos. 24 to 27 and 12 to 14 in overview). The guide sleeve side without a collar must be facing the shift sleeve side with the turned groove. The groove in the shift sleeve -A- must be facing the spacer during assembly.
Synchronization
Information
^ The stop cams -A- of the synchronizer ring must be positioned above the driver dogs -B-.
Stop cams of the synchronizer ring
4. Press synchronization onto the drive shaft using special tool assembly aid 9692 and special tool press-on sleeve 9694.
Synchronization on drive shaft
5. Heat inner bearing ring (no. 23 in overview) to approx. 150 °C and press it onto the drive shaft using special tool assembly aid 9692 and special tool press-on sleeve 9694.
6. Fit needle-roller bearing (no. 22 in overview) on the drive shaft at the correct position.
7. Fit loose gear wheel for 6th gear (no. 21 in overview) on the drive shaft.
8. Fit thrust washer (no. 20 in overview) on the drive shaft.
9. Heat inner bearing ring (no. 19 in overview) to approx. 150 °C and press it onto the drive shaft using special tool assembly aid 9692 and special tool press-on sleeve 9694.
10. Check synchronizer rings for 3rd/4th gear for wear. To do this, press the synchronizer rings onto the gear wheels and measure the gap -A- with a feeler gauge.
Synchronizer rings for 3rd/4th gear
The gap dimension A must be between 1.0 and 1.8 mm.
11. Fit needle-roller bearing (no. 18 in overview) on the drive shaft at the correct position.
12. Fit loose gear wheel for 3rd gear (no. 17 in overview) on the drive shaft.
13. Assemble synchronization (nos. 16 to 10 in overview). The groove in the shift sleeve -A- must be facing the spacer while you are pressing it on.
Synchronization
Information
^ The stop cams -A- of the synchronizer ring must be positioned above the driver dogs -B-.
Stop cams of the synchronizer ring
14. Press synchronization onto the drive shaft using special tool assembly aid 9692 and special tool press-on sleeve 9694.
Synchronization on drive shaft
15. Heat inner bearing ring (no. 9 in overview) to approx. 150 °C and press it onto the drive shaft using special tool assembly aid 9692 and special tool press-on sleeve 9694.
16. Fit needle-roller bearing (no. 8 in overview) on the drive shaft at the correct position.
17. Fit loose gear wheel for 4th gear (no. 7 in overview) on the drive shaft.
18. Fit thrust washer (no. 6 in overview) on the drive shaft.
19. Fit angular-contact ball bearing (nos. 3 to 5 in overview) on the drive shaft.
20. Fit output shaft with tensioning plate (no. 32 in overview) on the drive shaft. The drive and output shafts are held together by pressing on the thrust washer (no. 6 in overview) and the angular-contact ball bearing (nos. 3 to 5 in overview) using special tool assembly aid 9692 and special tool press-on sleeve 9694/1.
Output shaft with tensioning plate
21. Fit washer (no. 2 in overview) and circlip (no. 1 in overview) on the drive shaft.
Information
^ Always replace the circlip.
^ Insert the largest circlip that can still be fitted.
^ If the smallest circlip can no longer be fitted, use a thinner adjusting shim.
Fitting loose gear wheels on output shaft
Overview
Information
^ Add other pipes to the prescribed pressure pieces as required on all-wheel-drive vehicles.
Fitting loose gear wheels on output shaft
Warning
Preloaded or pressurized components
^ Risk of eye injuries
^ Risk of bruising
-> Wear personal protective gear.
-> Secure components to prevent them from falling off suddenly.
Information
^ The guide sleeves and inner bearing rings must be completely free of oil and grease before being fitted.
^ All components that turn and the synchronization parts must be lubricated with transmission oil before assembly.
1. Check synchronization for 2nd gear. To do this, place the friction ring (no. 27 in overview), cone ring (no. 26 in overview) and synchronizer ring (no. 25 in overview) on the gear wheel (no. 28 in overview). Measure the gap -A- with a feeler gauge. Perform the test again in the same way for 1st gear.
Synchronizer rings for 1st/2nd gear
The gap dimension A must be between 1.5 and 2.0 mm.
Information
When fitting a new needle-roller bearing, choose the largest needle-roller bearing that can be fitted from the parts kit and fit it.
2. Fit needle-roller bearing (no. 29 in overview) on the output shaft at the correct position.
3. Fit loose gear wheel for 2nd gear (no. 28 in overview) on the output shaft.
4. Insert friction ring (no. 27 in overview), cone ring (no. 26 in overview) and synchronizer ring (no. 25 in overview) into the guide sleeve (no. 24 in overview) and press onto the output shaft using special tool press-on sleeve 9694/3 (knurled side down!). The guide sleeve side with the large collar is facing the loose gear wheel for 2nd gear.
5. Heat inner bearing ring (no. 15 in overview) to approx. 150 °C and press it onto the output shaft using special tool press-on sleeve 9694/3 (knurled side down!) if necessary.
6. Fit shift sleeve (no. 20 in overview). The groove in the shift sleeve -A- must be facing the loose gear wheel for 2nd gear.
Synchronization
Information
^ The prick punch marks on the shift sleeve must be centered with respect to the recesses in the guide sleeve.
7. When fitting the shift sleeve, make sure that the prick punch marks on the shift sleeve are centered with respect to the recesses in the guide sleeve.
Fitting shift sleeve
1 - Shift sleeve
2 - Ball
3 - Driver dog
4 - Spring
A - Recognition groove
B - Prick punch mark
C - 2nd gear side
D - 1st gear side
8. Fit spring (no. 23 in overview), ball (no 22 in overview) and driver dog (no. 21 in overview). To do this, push the shift sleeve towards the loose gear wheel for 2nd gear.
9. Fit the synchronizer ring (no. 19 in overview), cone ring (no. 18 in overview) and friction ring (no. 17 in overview).
10. Fit needle-roller bearing (no. 16 in overview) on the output shaft at the correct position.
11. Fit loose gear wheel for 1st gear (no. 14 in overview) on the output shaft.
12. Press thrust washer (no. 13 in overview) onto the output shaft using special tool press-on sleeve 9694/3.
13. Heat inner bearing ring (no. 7 in overview) to approx. 150 °C and press it onto the output shaft using special tool press-on sleeve 9694/3 (knurled side down!) if necessary.
14. Check synchronizer ring for reverse gear for wear. To do this, press the synchronizer ring onto the gear wheel and measure the gap -A- with a feeler gauge.
Synchronizer ring
The gap dimension A must be between 0.85 and 1.4 mm.
15. Fit needle-roller bearing (no. 8 in overview) on the output shaft at the correct position.
16. Fit synchronization on the output shaft.
17. Fit synchronization on the output shaft.
18. Fit guide sleeve for reverse gear (no. 4 in overview) on the output shaft.
19. Press cylindrical-roller bearing (no. 3 in overview) onto the output shaft using special tool press-on sleeve 9694/3 (knurled side down!).
Cylindrical-roller bearing
20. Fit washer (no. 2 in overview) and circlip (no. 1 in overview) on the output shaft.
Information
^ Always replace the circlip.
^ Insert the largest circlip that can still be fitted.
^ If the smallest circlip can no longer be fitted, use a thinner adjusting shim.
Installing gear wheel set
Overview
Installing gear wheel set
1. Heat transmission housing (no. 25 in overview) for about 5 minutes using a hot-air gun and slide in gear wheel set (no. 24 in overview).
Information
^ Be careful with the adjusting shims (nos. 26 and 27 in overview).
2. Screw new fastening screws for tensioning plate (no. 23 in overview) into the housing and tighten in the correct sequence.
Tightening sequence for tensioning plate screws
Tightening torque 32 Nm (24 ftlb.)
Information
^ Always replace the shaft sealing ring for the drive shaft.
3. Fit differential (no. 22 in overview).
Information
Always replace the shaft sealing ring for the halfshaft flange.
4. Oil sealing ring for differential cover, fit differential cover (no. 21 in overview) and screw in screws (no. 20 in overview).
Tightening torque 26 Nm (19 ftlb.)
5. Insert halfshaft flange (no. 19 in overview) and screw in screws (no. 18 in overview).
Tightening torque 44 Nm (33 ftlb.)
6. Fit shift fork for 3rd/4th gear -A- on the shift sleeve.
Fitting shift fork on shift sleeve
7. Fit shift fork for 5th/6th gear -B- on the shift sleeve.
8. Guide shift rod for 5th/6th gear -D- through the shift fork for 5th/6th gear -B- into the transmission housing.
9. Guide shift rod for 3rd/4th gear -E- through the shift fork for 5th/6th gear -B-, through the shift finger guide -C- and through the shift fork for 3rd/4th gear -A- into the transmission housing.
10. Fix shift forks and shift rods as well as shift finger guide and shift rod in place with cotter pins.
11. Insert shifting shaft -C- into the transmission housing.
Inserting shifting shaft into transmission housing
12. Fit shift fork for 1st/2nd gear -B- on the shift sleeve.
13. Guide shift rod for 1st/2nd gear -A- through the shift fork for 1st/2nd gear -B- into the transmission housing.
14. Fix shift fork and shift rod in place with a cotter pin.
15. Guide shift rod for reverse gear - through the shift fork for reverse gear - into the transmission housing.
Shift rod for reverse gear
16. Fix shift fork and shift rod in place with a cotter pin.
17. Insert magnet (no. 6 in overview) into the transmission housing.
18. Install shift control lock device (nos. 7 to 9 in overview). Seal hexagon-head bolt with Loctite 574.
Tightening torque 14 Nm (10.5 ftlb.)
Fitting transmission cover
Information
^ The cardan shaft flange must be fitted after fitting the transmission cover on all-wheel-drive vehicles.
1. Position transmission cover and screw in screws.
Tightening torque 26 Nm (19 ftlb.)
Information
^ Check that the shift segment roller engages correctly in the shifting shaft.
2. Install switch interlock. To do this, fit the hexagon socket head bolt (A), compression spring (B) and locking pin (C). Seal hexagon socket head bolt (A) with Loctite 574.
Installing switch interlock
Tightening torque 23 Nm (17 ftlb.)
3. Fill with transmission oil.
4. Remove transmission from assembly support.
5. Install transmission.
Technical values
Tightening torques
-> Tightening torque: 32 Nm (24 ftlb.)
-> Tightening torque: 26 Nm (19 ftlb.)
-> Tightening torque: 44 Nm (33 ftlb.)
-> Tightening torque: 26 Nm (19 ftlb.)
-> Tightening torque: 14 Nm (10.5 ftlb.)
-> Tightening torque: 23 Nm (17 ftlb.)