Volkswagen Workshop Service and Repair Manuals

Installing l  A new deep groove ball bearing has been pressed onto the input shaft → Item.

–  First insert input shaft -1- and 5th and 6th gear output shaft -2- together with selector rod -3-, selector fork reverse gear -4- and reverse shaft -5-. Note different mounting for reverse gear selector fork.

Reverse gear selector fork -1- is mounted on shaft -2- behind selector rod for 5th and 6th gear -3-

Reverse gear selector fork -1- is mounted on selector rod with selector fork for 5th and 6th gear -2- Continuation for all

–  Then insert differential -1-.   Note A second mechanic will be required for further installation of shafts in clutch housing. –  Take output shaft for 1st through 4th gears -3- with selector rods -4- 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 input shaft and output shaft for 5th and 6th gears and reverse gear -2- together with reverse gear shaft. –  Now insert output shaft for 1st through 4th gears in -direction of arrow-. l  The teeth of the input shaft, the output shafts and the final drive input gear of differential must mesh. –  Now, together with a second mechanic, place shafts and differential in their bearing seats.

–  Secure support bridge -30-211A- for input shaft to clutch housing.   Note For clarity of illustration, clutch housing is shown turned 180°. –  Screw in bolt -A- until input shaft rises slightly.

Deep groove ball bearing of input shaft fits into gearbox housing in only one position There is a flat section on deep groove ball bearing and on the bearing support for the deep groove ball bearing. l  If the flats -A- and -B- are present, no washer must be placed above or below the deep groove ball bearing → Chapter. l  Flats -A- on deep groove ball bearing and on bearing support -B- in gearbox housing must line up. –  Mark flats with coloured marks. –  Transfer markings to upper area of deep groove ball bearing and to upper area of bearing support of gearbox housing (⇒ next diagram). –  Heat gearbox housing using, e.g. hot air blower -V.A.G 1416- for about 10 minutes to 100 °C in vicinity of seat for deep groove ball bearing of input shaft.   Note t  Heating is necessary to avoid damage to deep groove ball bearing when gearbox housing is installed. t  Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing.

t  Line up marking on deep groove ball bearing -A- with marking on gearbox housing -B- and set gearbox housing in place. –  Set gearbox housing in place and tighten bolts -A-, -B- and -C- to specified torque.

For steel bolts (external hexagon socket head bolts) as replacement part, note allocation: A -  Bolt with captive washer. B -  Bolt without washer. C -  Bolt with captive washer.

–  Install retaining ring -1- for deep groove ball bearing of input shaft. –  Install support bridge -30 - 211 A- for input shaft. –  If stop sleeve for selector shaft has been removed, now drive it in to stop of tool → Fig.. –  Turn gearbox in repair stand with opening for selector shaft upwards.

–  Insert selector shaft -1- in lower bearing -2- and in selector forks -3-.   Note For better clarity, sealing cover is removed in illustration.

–  Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop. l  Selector shaft cover -4- must be parallel to bolting surface on gearbox housing. l  Selector shaft must move freely in gate selection direction (upwards and downwards).   Note If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.

–  Tighten bolts -3- for selector shaft cover -4-. –  Screw in locking bolt -2-, ensuring that angled rod -arrow- is not engaged. –  Install reversing light switch -F4--1-.

–  Gearboxes for vehicles with start-stop system: fit gearbox neutral position sender -G701--arrow- and tighten securing bolt to specified torque → Item.

–  Drive in input shaft oil seal flush. –  Install slave cylinder with release bearing → Chapter. –  Shift through all gears. –  Install cover plate.

Cover plate identification -I- = sheet metal cover plate; secured with circlip -A- -II- = plastic cover plate; without circlip

Allocation

Receptacle for cover plate	Cover plate	Driving in
-Arrow A- = vertically	Made of sheet metal	→ Fig.
-Arrow B- = diagonal	Made of plastic	→ Fig.

Sheet metal cover plate –  Drive sealing cover plate into gearbox housing to stop of thrust piece.

–  Secure sealing cover plate with retaining ring -A-.

Plastic cover plate –  Drive sealing cover plate into gearbox housing to stop of thrust piece. Continuation for all l  Always observe cover plate allocation → Fig.. l  Leak may occur when installed incorrectly l  Cover plate → Electronic parts catalogue „ETKA“

–  Install flange shafts together with springs, thrust washers and tapered rings.

Gearbox for four-wheel drive Attach bevel box to gearbox as follows: –  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 and differential are centred when brought together. –  Align splines of right flange shaft and differential bevel gear, turning flange shaft if necessary. –  If the position of the splines and the centre guide is correct, then the bevel box will slide on as far as it will go against the gearbox.   Note Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off. –  Tighten the 4 connecting bolts -arrows- for bevel box to gearbox (only 3 are visible in figure). –  Tighten right flange shaft countersunk bolt with socket.