Volkswagen Workshop Service and Repair Manuals

Installing   Note t  Press bearing mounting with deep groove ball bearing onto input shaft and output shaft → Fig.. t  Press needle roller bearing sleeve for synchromeshed gear for 5th gear onto input shaft → Fig..

–  Position assembled components, input shaft -2- and output shaft -1- with bearing mounting for deep groove ball bearing, in thrust piece -T10080-. –  Insert selector mechanism (selector forks) -4- in the shaft locking collars. –  Install reverse gear shaft -3- with reverse gear.

–  Screw guide pin -T10079- onto stud (secures reverse gear) -arrow-. –  Insert components together into gearbox while guiding guide pin -T10079- through hole to secure selector mechanism in gearbox housing. –  Remove guide pin -T10079-. Note the following before pressing in: t  Correct engagement of selector forks in locking collars.

t  Check dimension -a- of output shaft splines.   Note t  Due to different spline heights, dimension -a-, output shafts of individual gearboxes have different lengths. t  To ensure that output shaft and input shaft are always pressed in evenly, it may be necessary to place a shim -T10083/1- (thickness 3 mm) onto input shaft. t  Therefore, measure dimension -a- of output shaft splines.

Dimension -a- = 30.6 mm

Placing shim -T10083/1- onto input shaft → Fig.

Place shim -T10083/1- onto input shaft and carefully press in bearing mounting together with input shaft and output shaft to stop

Carefully press in bearing mounting together with input shaft and output shaft to stop

–  Install bolt -A- for securing reverse gear wheel shaft. –  Install pivot pin -B- in bottom of gearbox.

–  Screw in reversing light switch -F4--C-. –  Install pivot pin -B- in top of gearbox. –  Place selector plates in neutral. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover. –  Install selector shaft with selector cover -A-. Then tighten bolts -arrows-.

–  Using new bolts -A-, tighten bearing mounting for input and output shafts.   Note Tighten bolts to specified torque, working from centre outwards using alternate sequence. –  Tighten hexagon flange nut -B- for securing selector mechanism (selector forks). –  Insert input and output shafts together with gearbox housing into thrust block -T10083-. –  Install gear wheel for 5th gear -1- and sleeve -2-.

Installation position, 5th gear wheel The high shoulder -arrow- faces gearbox housing cover. –  Install 5th gear synchromeshed gear -3- with needle bearing. –  Place 5th gear synchro-ring on synchromeshed gear.

Installation position, synchro-hub and locking collar for 5th and 6th gears The high shoulder -arrow- faces 5th gear and gearbox housing. –  Press on synchro-hub and locking collar for 5th and 6th gears → Fig..

–  Heat needle bearing for 6th gear to maximum 100° C and press on.   WARNING Wear protective gloves! –  Install 6th gear synchromeshed gear with needle bearing and synchro-ring.

–  Set thrust washer -A- in place.   Note t  Do not interchange inner races of cylindrical roller bearings of input and output shafts. t  For some gearboxes, the thrust washer -A- and the inner race for the cylindrical bearing -B- are combined in one component. l  They can be pressed on together only. –  Heat cylindrical roller bearing inner race -B- to maximum 100° C and press onto input shaft.   WARNING Wear protective gloves!

Installation position of gear wheel for 6th gear: High collar faces sleeve. –  Shift locking collar -A- for 5th and 6th gear to freewheel position to enable 6th gear synchromeshed gear to turn while gear wheel for 6th gear is being pressed on. –  Heat 6th gear wheel to maximum 100° C.   WARNING Wear protective gloves! –  Press on gear wheel for 6th gear, being careful that teeth of gear wheel -B- and synchronised gear for 6th gear -C- mesh.

–  Heat cylindrical roller bearing inner race -A- to maximum 100° C and press onto output shaft.   WARNING Wear protective gloves! –  Insert magnet in gearbox housing.

–  Install differential -A-. –  Apply sealant -AMV 188 200 03- evenly to sealing surface. –  Secure clutch housing to gearbox housing. –  Turn gearbox in support bracket so that gearbox housing is upwards.

–  Before tightening securing bolts -A-, engage 2 gears -arrows 1- to -3-.

–  Insert selector fork for 5th and 6th gears -2- and push pivot pin -1- in to stop -direction of arrow-. –  Apply sealant -AMV 188 200 03- evenly to sealing surface. –  Tighten gearbox housing cover.

–  Install both flange shafts with springs, thrust washers and tapered rings. –  Install clutch release lever together with release bearing and guide sleeve → Fig..