Transmission
Transmission
=> [ 5th Gear, Installing ]
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Needle Bearing Drift (VW 295)
• Driving Sleeve (VW 244 B)
• Inductive Heat Unit (V.A.G 1416)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Bracket (30-211 A)
• Driving Sleeve (32-111)
• Thrust Piece (T10030/4) from Assembly Tool (T10030)
• Tube 37 mm Dia. (VW 416 B)
• Puller (T10408)
• Thrust Piece (T10408/2)
• Plate (T10408/3)
• Support Bridge (T10323)
• Subframe Support Assembling Device (3253/7)
• Thrust Pad Con. 8/65 (VW 433)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Kukko Puller 65-160 mm (18/1) (Qty: 2)
• Inductive Heat Unit (VAS 6414)
• Sealing Paste (AMV 188 200 03)
• M8 x 100 mm Stud Bolt
Disassembly
- Secure the transmission to the transmission support (VW 353).
- Place a drip tray underneath.
- Open the oil fill and oil drain plugs.
- Drain the transmission fluid.
- Remove the clutch release lever, the release bearing and the guide sleeve. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
• Be careful not to damage the bearing for the input and output shafts when removing and installing 5th gear.
• When securing the transmission to the transmission support (VW 353) , install the following special tools for support:
Under the Input Shaft:
• Bracket (30 - 211 A)
• Driving Sleeve (32 - 111)
• Thrust piece (T10030/4)
- Secure the bolt on the bracket (30 - 211 A) with the nut - A -.
Under the Output Shaft Bracket:
• Support bridge (T10323)
• Subframe support assembling device (3253/7)
• Thrust pad con. 8/65 (VW 433)
- Remove the transmission housing cover - arrow -.
Remove the 5th gear selector fork as follows:
- Move the selector fork - 1 - into neutral.
- Remove the bolt - 2 - for the 5th gear selector fork shift jaw.
- Remove both selector for base bolts - arrows -.
- Remove the selector fork bases.
- Remove the 5th gear selector fork.
- It is not necessary to remove the spring - 3 - and the locking collar - 4 -.
- Engage 5th gear - arrow 1 - and 1st gear - arrows 2 and 3 - and then remove the bolts - A - for the synchronizer hub and for the 5th gear.
- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear cannot turn. Both bolts can now be loosened.
• Remove any locking fluid residue still in the threaded holes using a tap if the shafts are not going to be replaced.
- Remove both bolts - arrows - for the reverse shaft support.
- Remove the 3rd bolt - arrow - from the reverse shaft support.
- Move the gear shift shaft into neutral and remove the gear shift shaft with the gear shift cover. Remove the bolts - arrows - and pull the gear shift shaft out of the transmission housing.
- Remove the sealing cap - A - and support pins - B - from the bottom of the transmission.
- Remove the support pins - A - on the top side of the transmission and remove the transmission housing to clutch housing bolts - B - in the area of the differential.
- Remove the clutch housing to transmission housing bolts - A -.
• Do not remove the nuts - B - for the output shaft bearing support.
- Remove both flange shafts.
- Remove the flange shafts with the springs, thrust washers and tapered rings.
Remove the following components together with the transmission housing:
• 5th gear synchronizer hub
• 5th gear
• Both plates (T10408/3) must be attached to the 5th gear.
• The plates must be located above the 2 ribs on the housing, opposite each other - arrows -.
• There is a needle bearing under the 5th gear.
• Secure the plates so that the needle bearing does not touch the 5th gear when removing the transmission housing.
Use the puller (T10408) together with the following special tools:
• Thrust piece (T10408/2)
• Plates (T10408/3)
• Kukko puller 65-160 mm (18/1) (Qty: 2)
- Install the plates (T10408) to the threaded holes in the transmission housing cover using the bolts - A -.
A M7 x 35 bolts with washers
Tightening specification: 18 Nm
- Install the thrust pieces (T10408/2) on the shafts.
- Install Kukko puller 65-160 mm (18/1).
- Tighten the spindles - A - - on the Kukko puller 65-160 mm (18/21) 1/2 turn in an alternating order, to remove the 5th gear synchronizer hub, 5th gear and transmission housing.
- Heat the 5th gear slightly using the inductive heat unit (V.A.G 1416).
- Remove the selector forks - A - together with the rails.
- Remove the reverse gear selector fork - B -.
- Remove the nuts - B - for the output shaft bearing support.
- Remove the reverse gear - A -, the input shaft - B - and the output shaft - C -, one after the other, from the clutch housing.
- Remove the differential.
Assembly
- Install the differential.
- Always replace the seals - arrows - for the output shaft bearing support
• The illustration only shows 3 of the 4 seals.
- Insert input shaft - 1 - and the output shaft - 2 - together.
- Tighten the output shaft bearing support nuts to specification, see - item 11 - in => [ Input Shaft, Output Shaft, Differential and Shift Rods ] Transmission Components Overview.
- Install the reverse gear - 3 - on the needle bearing inside the clutch housing.
The shoulder - arrow - faces away from clutch housing.
- Make sure the reverse gear shaft - 4 - is complete, refer to => [ Reverse Shaft ] Reverse Shaft ; do not mount the support on the reverse gear shaft.
- Install the reverse gear shaft into the clutch housing.
- Clean all threaded holes in the reverse gear shaft support of locking fluid; the cleaning can be done with a thread tap.
- Mount the reverse gear shaft support.
- Install the reverse gear selector fork - 1 - with the support for the reverse gear selector fork - 2 -, the spring - 3 - and the sliding piece - 4 -.
Reverse gear location:
- Install the reverse gear selector fork - A -.
- Install the selector forks - B - together with the rails.
The reverse gear shaft supports - C - are located in front of the rails.
- Install the M8 x 100 stud bolts - A - into the reverse gear shaft support so that the shaft is aligned after fitting the transmission housing.
- Align the rails.
• The shift segments must be installed in the grooves on the locking collars.
- Apply sealing paste (AMV 188 200 03) evenly over the sealing surface on the clutch housing.
- Install the transmission housing and tighten the bolts to specification, see - item 15 - in => [ Transmission Housing and Shift Mechanism ] Transmission Components Overview.
Install the bolts for the reverse gear shaft support - arrow - as follows:
- Install the bolt - a -.
- Remove the M8 x 100 stud bolts - A - (see upper illustration).
- Install the bolt - c -.
Tightening sequence:
- Tighten the bolt - a - to 30 Nm.
- Tighten the bolt - b - to 25 Nm.
- Tighten the bolt - c - to 25 Nm (see upper illustration).
- Install the support pin - arrow - for the selector forks. To do this, align the shift mechanism using a screwdriver, so that the relevant support pin can be installed.
- Apply the sealing paste (AMV 188 200 03) evenly on the sealing surface on the sealing cover.
- Install the gear shift unit.
Install the gearshift shaft as follows:
- Move the gear shift rail into the neutral position.
- Apply the sealing paste (AMV 188 200 03) evenly on the sealing surface on the cover.
- Move the gear shift shaft into neutral.
- Position the selector shaft so that the selector finger - arrow - is inserted into the selector rails.
- Tighten the gear shift shaft cover bolts to specification, see - item 17 - in => [ Transmission Housing and Shift Mechanism ] Transmission Components Overview.
- Install both flange shafts with springs, thrust washers and tapered rings. For the tightening specifications, refer to one of the following:
=> [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
=> [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
5th Gear, Installing
• Make sure the bracket (30-211 A) and the support bridge (T10323) are installed.
- Secure the bolt on the bracket (30-211 A) with the nut - A -.
5th Gear, Installed Position:
The groove all the way around - arrow - faces the transmission housing.
- Heat the 5th gear to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414).
Wear safety gloves.
- Install the 5th gear.
Checking the 5th Gear Synchronizer Ring:
- Before reinstalling 5th gear and synchronizer ring, press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.
- Install the 5th gear selector gear with needle bearing.
- Place the 5th gear synchronizer ring onto the selector gear.
- If disassembled, assemble the 5th gear locking collar/synchronizer hub, refer to => [ Assembling the 5th Gear Locking Collar/Synchronizer Hub ] Input Shaft.
Installed Position of the 5th Gear Synchronizer Hub/Locking Collar:
The pointed teeth on the locking collar - arrow 1 - and the high collar on the synchronizer hub - arrow 2 - face the transmission housing.
The notches - arrow 3 - on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring (refer to => [ 5th Gear Synchronizer Ring with Cast Locking Pieces: ] ).
5th Gear Synchronizer Ring with Cast Locking Pieces:
- Cover all openings with cloths to prevent foreign objects from getting into the transmission.
- Heat the 5th gear synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414).
Wear safety gloves.
- Install the 5th gear synchronizer hub
• Make sure there is enough clearance when installing the synchronizer ring.
- Loosen the support for the input shaft.
- If it has not been done already, clean any locking fluid residue from the threaded hole for the synchronizer hub bolt and 5th wheel with a thread tap.
Otherwise, there is the danger that the bolts could shear off.
- Install the new synchronizer hub bolts and 5th gear.
Installed Position of the Concave Washers for 5th Gear and the 5th Gear Synchronizer Hub Bolts
The outer diameter - arrows - faces 5th gear.
- Engage 5th gear - arrow 1 - and 1st gear - arrows 2 and 3 - and then tighten the bolts - A - for the synchronizer hub and the 5th gear to specification, see - item 4 - in => [ Transmission Housing Cover and 5th Gear ] Transmission Components Overview.
- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear cannot turn. Both bolts can now be tightened
- Install the 5th gear selector fork.
Adjusting 5th Gear
- Shift into gear. Loosen the bolt - 1 -. Push the locking collar and the selector jaw in the - direction of the arrow -. Tighten the bolt - 1 - to 25 Nm.
• Measurement check: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.
- Install 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.
- Move the shift lever through all the gears.
- Install the transmission housing cover. Refer to => [ Transmission Housing Cover and 5th Gear ] Transmission Components Overview.
- Install the release bearing guide sleeve. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Fill the transmission fluid. Refer to => [ Pay attention to the following list for the subject - ] Transmission, Installing.