Passat Wagon L4-1.9L DSL Turbo (AHU) (1997)
Shifter M/T: Service and Repair
General Repair Instructions
REPAIR INSTRUCTIONS
General
Meticulous care and cleanliness and the correct servicing equipment are all necessary for achieving successful transmission repairs resulting in
satisfactory performance. It is understood that all normal basic safety rules are applicable.
A number of universally valid instructions for individual repair procedures formerly repeated at various points within the repair instructions are
summarized here. They are applicable to this repair information.
Transmission
When replacing transmission, refill with gear oil up to lower edge of filler hole
Refer to Specifications for fluid and capacity information
Ensure that the alignment sleeves fit properly between engine and transmission during installation
Gaskets And Seals
Replace paper gaskets
Thoroughly clean all joint surfaces before installation
Replace O-rings
Radial shaft seals
Before installation: Lubricate outer periphery of seal lightly and fill space between sealing lips with grease before installation.
After installation: Check transmission oil level; fill to lower edge of filler hole if necessary.
Retainers
Replace circlip
Do not over-stretch circlips
Circlips must seat fully in grooves
Replace spring pins
Installation position: Slot in direction of forces
Bearings
Install needle bearings with the side bearing inscription (thicker metal) toward the drift.
Coat all transmission bearings with gear oil before installing.
Lubricate especially thoroughly for bearing pre-load measurements.
Different taper roller bearings that are installed on the same shaft must always be replaced together. Use replacement bearings from the same
manufacturer whenever possible.
Heat bearing inner races to approx. 100°C (212°F) before installing.
Bearings and races are matched sets. Do not interchange outer and inner races for bearings of the same size.