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 assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
• ◆ When changing a gearbox fill with gear oil to the lower edge of the filler hole.
• ◆ Capacities and specifications .

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 and half-fill space between sealing lips -arrow- with grease G 052 128 A1.

After installation:

Check gearbox oil; if necessary top-up to lower edge of oil filler hole, specification => Page 00-3 .

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.
• ◆ Ensure with screwed connections that the areas of the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.
• ◆ Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a risk that the bolts will shear the next time they are removed.

Bearings

• ◆ Lubricate all gearbox bearings with gear oil before installing.
• ◆ Install needle bearings with lettered side (thicker metal) towards fitting tool.
• ◆ Taper roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings.
• ◆ Heat inner races to maximum 100°C before installing.
• ◆ Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.

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.

Selector gears

• ◆ Before pressing on, clean and heat on a hot plate to maximum 100°C.
• ◆ Temperature can be checked with temperature tester V.A.G 1558, ignition tester V.A.G 1767 or diesel tester V.A.G 1743.