Volkswagen Workshop Service and Repair Manuals

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful gearbox repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally valid instructions applicable for the various repair procedures - which were previously repeated a number of times at numerous places in the Workshop Manual - are summarised here. They apply to this Workshop Manual.

Gearbox

• ◆ When installing ensure that the dowel sleeves between the engine and gearbox are correctly located.
• ◆ When changing a gearbox, bevel box or rear final drive fill with gear oil.
• ‒ Capacities and specification => from Page 00-3 .

Gaskets, sealing rings

• ◆ Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
• ◆ Apply sealant uniformly but not too thick.
• ◆ Renew "O-rings".
• ◆ Radial shaft oil seals.

Before installing:

Lightly oil outer edge, fill space between sealing lips with grease.

After installation:

• ◆ Checking oil level in manual gearbox with bevel box
  .
• ◆ Checking oil level in rear final drive
  => Page 39-112 .

Locking devices

• ◆ Renew circlips.
• ◆ Do not overstretch circlips.
• ◆ Circlips must locate properly in the groove.

• ◆ → Renew spring pins
  Installation position: Slot longitudinal to line of force.

Bolts and nuts

• ◆ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
• ◆ Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten nuts and bolts in stages in a diagonal sequence.
• ◆ Tightening torques as specified are for unoiled bolts and nuts.
• ◆ Renew self-locking bolts and nuts.

Bearings

• ◆ Install needle bearings with lettered side (thicker metal) towards fitting tool.
• ◆ Lubricate all gearbox bearings with gear oil before installing.
• ◆ Taper roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings.
• ◆ Heat inner races to approx. 100 °C before installing.

• ◆ Do not interchange outer and inner races of bearings of the same size, bearings are paired.

Shims

• ◆ Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
• ◆ Check for burrs and damage.
• ◆ Only install perfect shims.

Synchronizer rings

• ◆ Do not interchange. When reusing always fit to the same gear.
• ◆ Check for wear and renew if necessary.
• ◆ Coat with gear oil before installing.

Gear wheels

• ◆ Before installing clean and heat on a hot plate to approx. 100 °C.
• ◆ Temperature can be checked with temperature tester V.A.G 1558.