Volkswagen Workshop Service and Repair Manuals

Assembly

–  Install primary and pinion shafts simultaneously on the bearing support, using Pressure shim -T 10083- and Pressure shim -T 10080-.

–  Install primary shaft -2-, and pinion shaft -1- with the bearing/ball bearing housing on the pressure part - T10085- –  Install the selection mechanism (selection forks) -4- on the shaft engaging sleeves –  Install the reverse gear wheel shaft -3- with gear. –  Install guide pin -T10079- on threaded pin (reverse gear fastening) -arrow-

–  Install all the components in the gearbox case, by directing the guide pin -T10079- into the case through the selection mechanism support hole. –  Release guide pin -T10079-. –  Before pressing on the bearing housing, check the correct fitting of the selection forks on the gearing sleeves.

–  Press carefully the bearing support with the primary and pinion shafts to the stop.

–  Install screw -A- on the reverse gear wheel shaft. –  Install bearing pins -B- on the lower transmission part.

–  Install reverse gear light switch -C-. –  Install bearing pins -B- on the upper transmission part. –  Place the selector in the “dead centre” position –  Apply Sealing putty -AMV 188 200 03- evenly on the selector cover's surface –  Install the selector lever shaft with the selector lever cover -A- . Then, tighten screws -arrows- → Item.

–  Install bearing supports on the primary and pinion shafts by using new screws -A-, tightening in cross and phased pattern, starting by the middle. –  Install hex nut -B- for the selection mechanism (selection forks).

–  Install differential -A-. –  Apply Sealing putty -AMV 188 200 03- evenly on the sealing surface of the transmission case –  Install the clutch case on the transmission case and tighten screws to the specified tightening torque → Item. –  Place the transmission with the clutch case facing upwards. –  Install the 5th gear wheel -1- with the needle bearing.

Installation position for 5th gear wheel The wide collar -arrow- shall point to the transmission case cover. –  Install the 5th gear synchroniser ring on the wheel. –  Install the complete 5th gear synchroniser with the gearing sleeve and stop ring.

–  Install the 5th gear selection fork -2- and push the bearing pin -1- to the stop, towards -arrow-. –  Determine the new circlip thickness -arrow- –  Identify and install circlip on the primary -3- and pinion -4- shafts. Circlips available

Thickness (mm)	Replacement parts No.
2,00	-085 311 187-
2,10	-085 311 187 A-
2,20	-085 311 187 B-

–  Install the transmission case cover.

–  Install propelling flanges. –  Install clutch lever with bearing and bearing guide → Fig. –  Fill with transmission oil → Chapter.