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Golf Mk6

General repair notes
General repair notes
Edition 12.2011, version 23.0
To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Of course, the basic rules for safety also apply during 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 this workshop manual.
Gearbox
t  When installing the manual gearbox, ensure that the dowel sleeves between the engine and gearbox are correctly seated.
t  When installing mounting brackets or waxed components, clean the contact surfaces. Contact surfaces must be free of wax and grease.
t  Allocate bolts and other components using the → Electronic parts catalogue (ETKA).
t  If the gearbox is repaired, fill with gear oil.
t  Capacity → Chapter.
Seals and sealing rings
t  Renew seals and gaskets.
t  After removing gaskets and seals, always inspect contact surface of housing or shaft for burrs or other signs of damage.
t  Lightly oil outer diameter of radial oil seals before installation.
   
t  Fill space between sealing lips half full with sealing grease -G 052 128 A1--arrow-
t  The open side of the oil seal faces the side with fluid filling.
t  After installing, check oil level and top up → Chapter
t  Lightly oil O-rings before installing; this prevents the rings being crushed when inserted.
t  Thoroughly clean parting surfaces and apply sealant -AMV 188 200 03-
t  Apply sealant uniformly but not too thick.
Sealant
t  Thoroughly clean housing joint surfaces before applying sealing paste.
t  Evenly apply a thin coat of sealing paste -AMV 188 200 03-.
t  Breather holes must remain free of sealing paste.
Locking devices
t  Renew retaining rings.
t  Do not overstretch retaining rings.
t  Retaining rings must locate properly in grooves.
  N32-0001
t  Renew spring pins. Installation position: slot must be in line with direction of force.
Nuts and bolts
t  Loosen and tighten securing bolts and nuts for covers and housings diagonally.
t  Do not cant especially delicate parts, such as clutch pressure plates. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
t  Torque settings are specified for unoiled bolts and nuts.
t  Always renew self-locking bolts and nuts.
t  Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if necessary.
t  Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subsequently being removed.
t  Check pitch of thread, to ensure correct thread chaser is used to clean threads and to ensure the threads are not damaged.
Bearings
t  Install new tapered roller bearings as supplied and do not lubricate additionally.
t  Install needle bearings with lettered side (thicker metal) towards fitting tool.
t  Tapered roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings.
t  Heat inner races to about 100 °C with the inductive heater -VAS 6414- before installing.
t  Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.
Shims
t  Measure shims at several points with a micrometer. The various thicknesses make it possible to achieve the exact shim thickness required.
t  Check for burrs and damage.
t  Install only flawless shims.
Synchro-rings
t  Do not interchange. When reusing synchro-rings, always fit to the same synchromeshed gear.
t  Check for wear and renew if necessary.
  V34-1515
t  Check grooves -arrow 1- of synchro-ring -A- and inner ring for flat spots (worn grooves).
t  If synchro-rings are coated, coating must not be damaged.
t  If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and inner friction surface -arrow 3- of this intermediate ring for »scoring«, »signs of abnormal wear« and »blue discolouration (due to overheating)«.
t  Check cone of synchromeshed gear for »scoring« and »signs of abnormal wear«.
t  Moisten synchromesh mechanism with gear oil before installing.
Gear wheels
t  Before installing, clean and heat with the inductive heater -VAS 6414- to maximum 100° C.
Synchromeshed gears
t  After assembly, check synchromeshed gears for slight play, or for freedom of movement.
Clutch
t  Ensure that the pressure plate does not cant: loosen and tighten bolts diagonally and in several gradual stages.
t  If the clutch has burnt out, thoroughly clean the clutch housing as well as the friction surface of flywheel with a cloth to reduce the smell of burnt linings.
  N35-10107

Safety precautions > < Overview - power transmission