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Golf Mk4

General repair notes
General repair notes
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  When exchanging a gearbox or bevel box, fill with gear oil.
t  Capacities and specifications → Chapter.
t  When changing a rear final drive, top up gearbox with gear oil and top up Haldex coupling with oil to lower edge of filler hole.
t  Capacities and specifications → Chapter.
Seals and sealing rings
t  Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
t  Apply sealant uniformly but not too thick.
t  Renew O-rings.
t  Radial oil seals.
Before installing:
   
Lightly oil outer diameter and half-fill space between sealing lips -arrow- with sealing grease for radial oil seal -G 052 128 A1-.
After installation:
t  Checking oil level in manual gearbox with bevel box → Chapter.
t  Checking oil level in rear final drive → Chapter.
Radial oil seal for propshaft flange and shaft bevel gear on rear final drive
t  Lightly oil around outside circumference and between sealing lips with high performance oil for Haldex couplings -G 052 175 A1-.
t  After installation, check oil level in Haldex coupling → Chapter.
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 longitudinal to line of force.
Nuts and bolts
t  Loosen and tighten securing bolts and nuts for covers and housings diagonally.
t  Loosen and tighten securing bolts and nuts for covers and housings diagonally.
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.
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 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.
t  Moisten with gear oil before installing.
Gear wheels
t  Before installing, clean and heat with inductive heater -VAS 6414- to maximum 100 °C.
Guided fault finding, vehicle self-diagnosis and testing
  V34-1515
t  Before performing repairs on the Haldex coupling, determine the cause of the fault as accurately as possible using vehicle diagnosis, testing and information system -VAS 5051- in modes of operation “Guided fault finding”, “Vehicle self-diagnosis” and “Test instruments”.
  W00-0706

Clutch, control > < Notes on performance test