Volkswagen Golf Workshop Service and Repair Manuals

Assembling

–  Insert needle thrust bearing with washers into input gear. 1 -  Needle thrust bearing washer 2 -  Needle thrust bearing 3 -  Needle thrust bearing washer, insert smooth side into input gear. 4 -  Input gear, installed in gearbox housing → Chapter.

–  Fit O-ring into planet carrier.   Note If planet carrier is renewed, adjust planet carrier. → Chapter.

–  Insert small sun gear with washer and needle thrust bearing into planet carrier. 1 -  Needle thrust bearing t  Outer Ø: 41 mm t  For gearboxes 01.93 ► → Chapter, outer Ø: 39.1 mm 2 -  Needle thrust bearing washer 3 -  The small sun gear cannot be removed from planet carrier in gearboxes 01.93 ► → Chapter. 4 -  Planet carrier

–  Fit planet carrier into input gear. –  Centre washer and needle thrust bearing in “small sun gear”. –  Insert inner and outer -B1- plates. –  Insert pressure plate with flat side facing plates. The thickness of the pressure plate depends on the number of plates → Item.

–  Insert dished washer with convex side facing freewheel.   Note t  When replacing t  Gearbox housing t  Freewheel t  Piston for reverse gear brake -B1- t  or the plates t  then adjust reverse gear brake -B1- → Chapter.

–  Preload freewheel rollers with assembly ring -3267- and insert freewheel.

–  Install retaining ring for freewheel -b- and retaining ring for support tube -a-. –  Position gaps of retaining ring on freewheel retaining wedge -arrow-. –  Check dimensions of -B1- → Chapter.

–  Insert washer with needle thrust bearing in large sun gear. 1 -  Needle thrust bearing 2 -  Washer with shoulder, smooth side to needle thrust bearing 3 -  Large sun gear

–  Insert large sun gear with bearing. –  Centre washer with needle thrust bearing between the two sun gears.

–  Set needle thrust bearing and needle bearing in large input shaft.

–  Insert large input shaft with bearing.

–  Insert small input shaft.

–  Install bolt for small input shaft -1- with washer -2- and shim -3-, torque setting 30 Nm.   Note t  Set shim -3- onto small input shaft shoulder -arrow-. t  Determining shim thickness, Adjusting planet carrier → Chapter. –  Check dimensions of planet carrier → Chapter.

–  Insert needle thrust bearing with washers into -K3-. 1 -  Needle thrust bearing washer 2 -  Needle thrust bearing 3 -  Needle thrust bearing washer, insert with smooth side facing -K3- 4 -  3rd and 4th gear clutch -K3- For gearboxes 01.93 ► → Chapter, clutch -K3- shifts only 4th gear.   Note Make sure that the piston rings are correctly located.

–  Place needle thrust bearing with washer on 3rd and 4th gear clutch -K3-. 1 -  Needle thrust bearing with washer Moisten needle thrust bearing washer with ATF so that bearing adheres to -K3- during installation. Place washer of bearing onto -K3-. 2 -  3rd and 4th gear clutch -K3-

–  Insert 3rd and 4th gear clutch -K3-. For gearboxes 01.93 ► → Chapter, clutch -K3- shifts only 4th gear.

–  Insert shims -a- into -K1-.   Note t  If -K1-, -K2- or ATF pump is renewed, shim must be measured again ⇒ Adjusting clutch play between -K1- and -K2- → Chapter. t  There may be 1 or 2 shims installed.

–  Insert 1st to 3rd gear clutch -K1-. –  Insert reverse gear clutch -K2-.

–  Insert support tube for -B2- plate set -arrow- so that groove in support tube engages in wedge of freewheel.

Install -B2- plates as follows: –  First insert a 3 mm thick outer plate. –  Insert three spring caps in outer plate. –  Insert compression springs -arrows-. –  Insert all but the last outer plate.

–  Before inserting last (measured) outer plate, set the three spring caps on compression springs.   Note t  When replacing t  Support tube t  the ATF pump t  or the plates t  then adjust the 2nd and 4th gear brake -B2-, → Chapter. –  Insert corrugated washer. –  Insert ATF pump seal. –  Fit O-ring on ATF pump.

–  Insert ATF pump. –  Tighten bolts evenly and diagonally.   Note t  Ensure that O-ring is not damaged in the process. t  Torque setting: 8 Nm. –  Then turn bolts 90° further. Turning further can be done in several stages. –  Check dimension of clutch play → Chapter. –  Install valve body with conductor strip and ATF pan → Chapter. –  Install cover with gasket and spacer bushes.