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Clutch, control > < Contact corrosion!

A3 Mk1

General repair instructions
General repair instructions
Proper tools and the maximum possible care and cleanliness are essential for satisfactory gearbox repairs. The usual basic safety precautions also naturally apply when carrying out repair work.
A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places in the Workshop Manual - are summarised here. They apply to the work described in this Manual.
Special tools
For a complete list of special tools used in this Workshop Manual → "Special tools, Workshop equipment"
Gearbox
t  When installing manual gearbox, ensure that the dowel sleeves between the engine and the gearbox are correctly located.
t  When renewing a gearbox, fill with gear oil to the bottom lip of filler hole. Checking gear oil level → Chapter.
t  Capacity → Chapter.
t  For gear oil specification, refer to → Electronic parts catalogue.
O-rings, oil seals and gaskets
t  Always renew O-rings, seals and gaskets.
t  After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
t  Clean joints thoroughly and apply sealant -AMV 188 200 03-.
t  Apply sealant evenly but not too thickly.
   
t  Before installing oil seals, lightly oil the outer circumference of the seal and fill the space between the sealing lips -arrow- about half full with grease -G 052 128 A1-.
t  The open side of the oil seals faces toward the side with fluid filling.
t  When installing a new oil seal, position the seal in the housing so that the sealing lip does not contact the shaft in the same place as the old seal (make use of installation depth tolerances).
t  Lightly lubricate O-rings before installation to prevent them from being trapped and damaged during assembly.
t  After renewing seals and gaskets, check and, if necessary, top up oil level in final drive → Chapter; gear oil specification → Electronic parts catalogue.
Locking elements
t  Do not over-stretch circlips.
t  Always renew circlips which have been damaged or over-stretched.
t  Circlips must be properly seated in the base of the groove.
  N32-0001
t  Renew spring pins. Position: the slit -A- should be in line with the line of force -arrow-.
  A34-0149
Nuts, bolts
t  Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
t  Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
t  Loosen and tighten particularly sensitive parts in diagonal sequence and in stages, taking care to keep them straight.
t  The tightening torques stated apply to non-oiled nuts and bolts.
t  Always renew self-locking bolts and nuts.
t  For all threaded connections, ensure that (where applicable) the contact surfaces and the nuts and bolts are not coated with wax until after assembly is completed.
t  Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a danger of the bolts shearing off the next time they are removed.
Bearings
t  Install new tapered roller bearings as supplied; do not lubricate additionally with oil.
t  Lubricate all bearings (except tapered roller bearings) with gear oil before installing in gearbox.
t  Always renew the tapered roller bearings on one shaft together. Use new bearings from a single manufacturer wherever possible.
t  Use inductive heater -VAS 6414- to heat inner races of tapered roller bearings to approx. 100°C before installing. Press home onto stop when installing so there is no axial clearance.
t  Do not interchange the outer or inner races of bearings of the same size (the bearings are paired).
t  Install needle bearings so the lettering (side with thicker metal) faces towards the installing tool.
  N00-0383
Shims
t  Measure shims at several points with a micrometer. Tolerance variations make it possible to obtain the exact shim thickness required.
t  Check for burrs and damage.
t  Install only shims which are in perfect condition.
Synchro-rings
t  Do not interchange. When reusing synchro-rings, always fit to the same selector gear.
  N30-10156
t  Check for wear (gap -a-); renew if necessary.
t  Check grooves on synchro-ring for wear (flattened sections in grooves).
t  Make sure that the coating of coated synchro-rings is not damaged.
t  Check chamfer on selector gear for scoring and visible traces of wear.
t  Lubricate synchro-rings with gear oil before installing.
Gears, synchronising hubs, inner rings for selector gears
t  Before installing, heat inner rings for selector gears to approx. 100° C using inductive heater -VAS 6414-.
t  Use inductive heater -VAS 6414- to heat gear wheels and synchronising hubs to approx. 100°C before installing. Press home onto stop when installing so there is no axial clearance.
t  Note correct installation position.
Selector gears
After installing, check 1st to 5th selector gears for minimal axial play and freedom of movement.
Clutch actuation
t  When removing gearbox, remove clutch slave cylinder without disconnecting pipes.
t  Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic pipe is still connected. Otherwise the piston will be pressed out of the clutch slave cylinder.
t  Ensure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in several gradual stages.
t  If the clutch pedal does not return to its initial position after releasing it (clutch pedal in rest position), you must bleed the clutch system (further measures → Chapter „Checking hydraulic clutch mechanism“).
t  If the clutch has burnt out, thoroughly clean the clutch housing, flywheel and parts of the engine facing the gearbox in order to reduce the smell of burnt linings.
  V35-0975

Clutch, control > < Contact corrosion!