Volkswagen Workshop Service and Repair Manuals

Installing

–  Insert differential -1-. –  Install output shaft for 5th, 6th and reverse gears -2- together with reverse gear selector fork, selector rod for 5th and 6th gears -3- and reverse shaft -4-.

–  Take output shaft for 1st through 4th gears -3- with selector rods -5- in the right hand as shown in figure. –  With the left hand, lift differential slightly. –  At the same time, a 2nd mechanic must slightly lift output shaft for 5th, 6th and reverse gears -2- together with reverse gear shaft -4-. –  Now insert output shaft for 1st through 4th gears in direction of arrow. The teeth of the output shafts must mesh with the final drive input gear of differential. –  Now, together with a second mechanic, place shafts in their bearing seats.

–  Set input shaft in clutch housing and swing in -arrow-.

From gearbox date 06 04 0 –  Insert locking plate -arrow- in recess of tapered roller bearing outer race for input shaft. –  Tighten new bolt to specified torque → Item. Continued for all gearboxes –  Fit gearbox housing.

Install selector shaft as follows: –  Move selector rods to neutral. –  Insert selector shaft -1-. –  Position selector shaft so that shift fingers are inserted in selector rods → Fig.. –  When doing this, align lower selector shaft bearing -arrow- through drilling for cover plate. –  Bolt cover plate -A- to lower selector shaft bearing -1- with bolt -2- M8 x 60 mm.

–  Hand tighten cover plate -A- by alternately tightening (1/2 turn) bolts -arrows-. –  Remove bolt -2- and hand-tighten original bolt in its place. –  Install selector mechanism cover -B- and tighten hexagon bolts -4- to specified torque. –  Now tighten hexagon bolts for cover plate. –  Insert securing bolt -3- for selector shaft guide with locking fluid -D 000 600 A2-. –  Install reversing light switch. –  Install left flange shaft together with spring, thrust washer and tapered ring. –  Install speedometer sender.

–  Drive in input shaft oil seal. –  Fit slave cylinder with release bearing. Install bevel box as follows:

–  Always renew O-ring for sealing bevel box and gearbox -arrow A- and O-rings for sealing sleeves for oil supply system -arrow B- and -arrow C-, lightly coating with oil. –  Grease splines of differential with grease for clutch plate splines -G 000 100-. –  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft are guided centrally onto differential connecting piece. –  Align splines of right flange shaft and differential bevel gear, turning flange shaft if necessary. –  If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox. –  Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.

–  Install four bevel box/gearbox connecting bolts (only three shown in figure) -arrows-. –  Tighten right flange shaft countersunk bolt with socket -V.A.G 1669- or commercially available 6 mm socket insert and hold against turning with drift.