Volkswagen Workshop Service and Repair Manuals

Installing –  Install differential. –  Insert output shaft. –  Tighten bolts for output shaft bearing support.

–  Installation position of needle bearing thrust washer for 1st gear synchromeshed gear:    Shoulder -A- on inner circumference faces bearing support -B-. –  Fit thrust washer, needle bearing, gear wheel and synchro-ring for 1st gear.

–  Installation position for 1st and 2nd gear locking collar and synchro-hub    Identification groove on face -A- and outer splines of locking collar -B- face 1st gear synchromeshed gear -C-.

–  Heat locking collar and synchro-hub for 1st and 2nd gear to approx. 100° C, set in place and drive on to stop.    Turn synchro-ring so that grooves align with locking pieces. –  Install reverse gear, driving in shaft if necessary.

–  Drive on inner race for needle bearing for 2nd gear synchromeshed gear to stop. –  Fit needle bearing, synchro-ring, synchromeshed gear for 2nd and gear wheel for 3rd gear.

Installation position, gear wheel for 3rd gear Collar -arrow- towards 2nd gear synchromeshed gear -A- –  Drive on gear wheel for 3rd gear to stop using drift sleeve -VW 244 B-.

Adjust axial play of gear wheel for 3rd gear as follows: –  Determine thickest retaining ring which will still fit and install it.

Thickness (mm)	Identification
2.5	Brown
2.6	Black
2.7	Polished
2.8	Copper
2.9	Brass
3.0	Blue

Part numbers of retaining rings → Electronic parts catalogue (ETKA)

–  Assemble support bridge -30 - 211 A- for input shaft.   Note If input shaft was not dismantled: pressing off deep groove ball bearing for input shaft → Item. –  Fit complete input shaft but without deep groove ball bearing. –  Lift adapter -VW 295 A- over bolt to stop on input shaft and lock nut -A-. A -  Lock nut M 12

Installation position, gear wheel for 4th gear Collar -arrow- faces 5th gear splines -A-. –  Fit gear wheel for 4th gear on output shaft using extension -30 - 23- and secure with retaining ring.

–  Press on input shaft deep groove ball bearing. Installation position: Wider collar -arrow- of inner race faces press tools.

–  Tighten tensioning plate -arrow- securely.   Note Tensioning plate fits only in one position.

–  Insert lower spring -arrow- for selector rod into clutch housing.

–  Install selector fork set and align selector jaws. A -  Selector fork for 1st and 2nd gear -arrow- faces notch for selector bridge -C-. B -  3rd/4th gear selector fork C -  Selector bridge with selector tube for 5th gear D -  Selector fork for reverse gear –  Push in selector rods.

–  Align reverse gear wheel shaft. Distances -x- are identical.

–  Drive on gearbox housing. –  Bolt on reverse gear wheel shaft. –  Tighten hexagon bolts for securing gearbox housing to 25 Nm. –  Retighten tensioning plate countersunk screws for deep groove ball bearing to 15 Nm. –  Drive on gear wheel for 5th gear.

Installation position: Groove -arrow- faces upwards. –  Install thrust washer and retaining ring. –  Fit 5th gear synchro-hub complete with locking collar, 5th gear synchromeshed gear with selector fork and new securing plate. –  Use box spanner -3059- to screw selector tube clockwise into selector fork.

–  Unscrew selector tube until it projects -x- = 5.0 mm.   Note Do not pull selector rod out of the selector tube (may happen if box spanner is tilted). Otherwise the selector forks in the gearbox will fall apart and the gearbox will have to be disassembled again. Hold selector rod down, if necessary, with a screwdriver inserted through the side slot when taking box spanner off. –  Coat new bolt for synchro-hub with locking fluid -D 000 600 A2- and start bolt.

–  Engage 5th gear -arrow 1-. –  Engage reverse gear -arrow 2- (front selector jaw downwards). –  Tighten synchro-hub bolt with a 12 mm multi-point key. –  Move selector forks to neutral position.

–  Insert selector shaft -1-. –  Insert compression spring -2- for selector shaft and tighten sealing cover -3-.   Note If the sealing cover was sealed with a sealing ring -4-, then this sealing ring must be renewed. Through gearbox date 02 08 8 –  Insert selector shaft locking bolt -5- with locking fluid -AMV 188 200 03-. From gearbox date 03 08 9

–  Screw in reversing light switch -1-. –  Screw in selector shaft locking bolt -2- with locking fluid -AMV 188 200 03-. Continued for all gearboxes Adjust 5th gear selector fork as follows: l  Perform adjustment with great care to prevent gears from “jumping out”.

–  Check projection of selector tube - dimension -x- = 5.0 mm. Adjust with box spanner -3059- if necessary. –  Bolt selector shaft lever to selector shaft and engage 5th gear (pull selector shaft fully out and turn to left).

–  Align locking collar -1- with selector fork -2- to 5th gear synchromeshed gear -3- so there is no play. l  Check measurement: there must be a gap -a- = 1.3 mm between locking collar and synchromeshed gear. Correct dimension, if necessary by turning selector tube. –  Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.

–  Drive on new locking plate. Support selector fork with tools about 12 mm thick, e.g. two flat open jaw spanners (19 mm and 24 mm) -A-. –  Shift through all gears.

–  Fit gearbox housing cover -arrow- (Qty. 6 bolts).   Note One of the 6 bolts is located inside the cover.

–  Then insert release bearing -A- into gearbox housing cover.

–  Drive on sealing cover.   Note Sealing surface on gearbox housing cover must be free of grease.

–  Install both flange shafts with springs, thrust washers and tapered rings. –  Remove support bridge -30 - 211 A- for input shaft.

–  Guide clutch push rod -A- into input shaft