Transmission
Transmission
Removing and installing transmission housing cover, clutch housing, shift rod with shift cover, input shaft, output shaft (pinion shaft), differential and shift mechanism.
Special tools, testers and auxiliary items required
• Driving sleeve (VW 244 B)
• Needle bearing drift (VW 295)
• Holding plate (VW 309)
• Transmission support (VW 353)
• Tube 37 mm dia. (VW 416 B)
• Bracket (30 - 211 A)
• Driving sleeve (32 - 111)
• Torque wrench 5 to 50 Nm (V.A.G 1331)
• Torque wrench 40 to 200 Nm (V.A.G 1332)
• Heat gun (V.A.G 1416)
• Drip tray for shop crane (VAS 6208)
• Thrust piece (T10030/4)
• Two arm puller (Kukko 20/10 )
• Hook (Matra V/170)
• (Stud M 8 x 100 mm)
• Hex bolt, M10 x 20
Disassembling
- Secure transmission to assembly stand.
- Place drip tray for shop crane (VAS 6208 ) underneath.
- Open oil filler bolt and oil drain bolt.
- Drain gear oil.
- Remove clutch release lever, release bearing and guide sleeve => [ Clutch Release Mechanism ] Clutch Release Mechanism.
- Remove transmission housing cover - arrow -.
Remove shift fork and locking collar for 5th gear as follows:
- Cover openings with a cloth.
- Move shift fork - 1 - into neutral position.
- Remove bolt - 2 - with shift jaw for 5th gear.
- Remove both bolts - arrows - for pivot pins.
- Pull out pivot pins.
- Remove shift fork.
- Spring - 3 - must now be removed.
- Pull off locking collar - 4 - and remove locking pieces at the same time.
- Slide 5th gear locking collar over synchronizer hub again.
- Remove bolts - A - for synchronizer hub and gear wheel for 5th gear. To do this select 5th gear - arrow 1 - and 1st gear - arrow 2 - and - arrow 3 -.
- After engaging both gears, input shaft and output shaft are locked, synchronizer hub and gear wheel cannot be turned. Now, both bolts can be loosened.
• If shafts are not replaced, carefully clean threaded bores from locking fluid residue using a tap.
- Pull of synchronizer hub with drive gear for 5th gear and remove with needle bearing.
A Two arm puller, e.g. (Kukko 20/10) with hook (Matra V/170)
B Hex bolt, M10 x 20
- Pull off drive gear for 5th gear.
A Two arm puller, e.g. (Kukko 20/10) with hook (Matra V/170)
B Hex bolt, M10 x 20
Disassembly sequence:
- Install two arm puller and center by rotating bolt - arrow -.
- Pull off drive gear using two arm puller. If necessary, preheat with heat gun (V.A.G 1416).
• When pulling off drive gear, make sure that hooks do not bend toward the outside, retighten bolt - arrow -. After pulling off drive gear, check for damage.
- Remove bolt for left and right flange shaft. To do this, screw two bolts into flange and counter-hold flange shaft centrally using a pry bar.
- Remove flange shafts with compression springs, thrust washers and tapered rings.
- Remove both bolts - arrows - for reverse gear shaft support.
- Remove 3rd bolt - arrow - for reverse gear shaft support.
- Remove shift rod with shift cover. To do this, move shift rod into neutral position. Then remove bolts - arrows - and pull shift rod out of transmission housing.
- Remove sealing cap - A - and pivot pins - B - on underside of transmission.
- Remove bolts - A - from clutch housing, securing clutch housing to transmission housing.
• Do not remove nuts - B - for bearing mount of output shaft.
- Remove pivot pins - A - on top side of transmission and bolts - B - for transmission housing to clutch housing in area of differential.
- Remove transmission housing, carefully pry off all around and alternating between sides on protruding flanges - arrows -. Do not damage sealing surfaces while doing so.
- Remove shift forks - A - together with shift rails.
- Unfasten reverse gear shift mechanism - B -.
- Remove nuts - B - for output shaft bearing mount.
- Remove reverse gear - A -, input shaft - B - and output shaft - C - from clutch housing in sequence.
- Remove differential.
Assembling
- Install differential.
- Always replace seals - arrows - for output shaft bearing mount.
• Illustration shows only 3 of 4 seals.
- Install input shaft, output shaft and reverse gear shaft together.
- Tighten nuts for output shaft bearing mount.
- Install reverse gear shift mechanism.
- Clean locking fluid residue from threads for bolts - a - and - c - in reverse gear shaft support - arrow -. The residue can be removed using a thread tap.
- Set reverse gear shaft support onto reverse gear shaft.
- Insert reverse gear shaft into transmission housing.
- Install reverse gear shift fork - 1 - with support for reverse gear shift fork - 2 - of spring - 3 - and sliding piece - 4 -.
Installation position for reverse gear:
- Thread in bolt - A - for shift mechanism/reverse gear and tighten.
- Install shift forks - B - together with shift rails.
The end - C - of reverse gear support is located in front of shift rails.
- Thread M8 x 100 mm stud - A - in support for reverse gear shaft to align reverse gear shaft after installing transmission housing.
- Align shift rails.
• The shift segments must be positioned in the grooves on the locking collars.
- Apply sealant (AMV 188 200 03) evenly to sealing surface of clutch housing.
- Install transmission housing.
Install bolts for reverse gear shaft support - arrow - as follows:
- Insert bolt - a -.
- Remove stud - A - (illustration V34-2008 ).
- Insert bolt - c -.
Tightening specification:
- Tighten bolt - a - to 30 Nm.
- Tighten bolt - b - to 25 Nm.
- Tighten bolt - c - (illustration N34-1806 ) to 25 Nm.
- Install pivot pin - arrow - for shift forks. To do this align shift mechanism with a screwdriver, so that the relevant pivot pin can be installed.
- Apply sealant (AMV 188 200 03) evenly to sealing surface of sealing cover.
- Install sealing cover for shift rod.
Install shift mechanism as follows:
- Move shift rails to neutral position.
- Apply sealant (AMV 188 200 03) evenly to sealing surface of shift cover.
- Move shift rails to neutral position.
- Position shift rod so that shift finger - arrow - is inserted into shift rails.
- Fasten shift cover for shift rod.
Installed Position of Drive Gear for 5th Gear
Circumferential groove - arrow - faces transmission housing.
- Drive on drive gear for 5th gear.
- Install bracket (30 - 211 A).
- Press driving sleeve (32 - 111) onto input shaft up to stop via bolt and counter with nut - A -.
Check 5th Gear Synchronizer Ring
- Before reinstalling shift gear and synchronizer ring for 5th gear, press synchronizer ring onto taper of shift gear and measure gap dimension - a - using a feeler gauge.
- Install 5th gear shift gear with needle bearing.
- Place 5th gear synchronizer ring onto shift gear.
- If disassembled, assemble 5th gear synchronizer hub/locking collar before installing => [ Assembling 5th gear locking collar/synchronizer
hub ] Input Shaft
Installation Position of 5th Gear Synchronizer Hub/Locking Collar
The pointed teeth of locking collar - arrow 1 - and high shoulder of synchronizer hub - arrow 2 - face toward transmission housing.
The notches - arrow 3 - of synchronizer hub are aligned with cast locking pieces of synchronizer ring=> [ 5th Gear Synchronizer Ring with Cast Locking
Pieces ]
5th Gear Synchronizer Ring with Cast Locking Pieces
- To prevent foreign bodies from entering the transmission, cover all openings with a cloth.
- Drive on synchronizer hub for 5th gear.
• When driving on, make sure synchronizer ring is free to move.
Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Securing Bolts
Outside diameter - arrows - faces 5th gear.
- Fasten bolts - A - for 5th gear synchronizer hub and drive gear to tightening specification. To do this, engage 5th gear - arrow 1 - and 1st gear - arrow 2 - and - arrow 3 -.
- After engaging both gears, the input shaft and output shaft are locked, synchronizer hub and drive gear cannot turn. Now both bolts can be tightened.
- Install 5th gear shift fork.
Adjusting 5th Gear
- Engage 5th gear. Remove bolt - 1 -. Press locking collar and shift jaw in direction of - arrow -, then tighten bolt - 1 - to 25 Nm.
• Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and drive gear. If necessary, repeat adjustment.
- Disengage 5th gear. Locking collar must now be in the neutral position. Synchronizer ring must move freely.
- Shift through all gears.
- Install transmission housing cover.
- Install both flange shafts with springs, thrust washers and tapered rings.
- Fasten flange shafts with countersunk screw and tighten to 25 Nm.
- Install guide sleeve for release bearing => [ Clutch Release Mechanism ] Clutch Release Mechanism.
- Install clutch release lever and release bearing => [ Clutch Release Mechanism ] Clutch Release Mechanism.
- Fill up gear oil => [ Observe the Following Assembly
for ] Transmission, Installing.