Volkswagen Workshop Service and Repair Manuals

Installing l  A new deep groove ball bearing has been pressed onto the input shaft → Item.

–  Insert input shaft -1-, output shaft for 5th and 6th gears -2- together with selector rod -3-, selector fork -4- and reverse shaft -5-.

–  Then insert differential -1-.   Note A second mechanic will be required for further installation of shafts in clutch housing. –  Take output shaft for 1st through 4th gears -3- with selector rods -4- in the right hand as shown in figure. –  With the left hand, lift differential slightly. –  At the same time, a 2nd mechanic must slightly lift input shaft and output shaft for 5th and 6th gears and reverse gear -2- together with reverse gear shaft. –  Now insert output shaft for 1st through 4th gears in -direction of arrow-. l  The teeth of the input shaft, the output shafts and the final drive input gear of differential must mesh. –  Now, together with a second mechanic, place shafts and differential in their bearing seats.

–  Secure support bridge -30 - 211 A- for input shaft to clutch housing.   Note For clarity of illustration, clutch housing is shown turned 180°. –  Screw in bolt -A- until input shaft rises slightly. From gearbox date 10 04 6, gearbox housing has been modified. A washer is installed above and one below the deep groove ball bearing for the input shaft → Item.

Upper washer	Outer diameter	78.6 mm
Lower washer	Outer diameter	85 mm

–  Check the gearbox housing.

–  Measure distance above seat for deep groove ball bearing. The shoulder has been machined to accommodate the washer.

Distance above deep groove ball bearing	Dimension „a“	Washer
From gearbox date 10 04 6	10.7 mm	yes
Through gearbox date 09 04 6	10 mm	no

The bearing seat in the gearbox housing for the deep groove ball bearing has also been modified from gearbox date 10 04 6. The bearing seat -arrow- for the deep groove ball bearing (-2- ⇒ figure below) has also been machined slightly to accommodate the washer (-1- ⇒ figure below).

From gearbox date 10 04 6, lay a washer with an outer diameter of 85 mm -1- on the deep groove ball bearing -2-. –  Heat gearbox housing using, e.g. hot air blower -V.A.G 1416- for about 10 minutes to 100 °C in vicinity of seat for deep groove ball bearing of input shaft.

–  Set gearbox housing in place and tighten bolts -A-, -B- and -C- to specified torque. For steel bolts (external hexagon socket head bolts) as replacement part, note allocation: Allocation of bolts: A -  Bolt with captive washer B -  Bolt without washer C -  Bolt with captive washer

From gearbox date 10 04 6, insert a washer with an outer diameter of 78.6 mm -1- above the deep groove ball bearing -2-.

–  Install retaining ring -1- for deep groove ball bearing of input shaft. –  Remove support bridge -30 - 211 A- for input shaft.

–  If stop sleeve for selector shaft has been removed, now drive it in to stop of tool using drift -T10168-. –  Turn gearbox in repair stand with opening for selector shaft upwards.

–  Insert selector shaft -1- in lower bearing -2- and in selector forks -3-. For reasons of clarity, sealing cover is removed in figure.

–  Now press selector shaft -1- against stop sleeve -2- in -direction of arrow- and guide downwards with selector finger -3- through selector forks to stop. l  Selector shaft cover -4- must be parallel to bolting surface on gearbox housing. l  Selector shaft must move freely in gate selection direction (upwards and downwards).   Note If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.

–  Tighten bolts -3- for selector shaft cover -4-. –  Screw in locking bolt -2-, ensuring that angled rod -arrow- is not engaged. –  Install reversing light switch -F4--1-. –  Install flange shaft and stub shaft with compression springs, thrust washers and tapered rings.

–  Drive in input shaft oil seal flush. –  Install slave cylinder with release bearing. –  Shift through all gears.

–  Drive sealing cover into gearbox housing to stop using thrust piece -T10042-. Attach bevel box to gearbox as follows:

–  Always renew O-ring for sealing bevel box and gearbox -arrow A- and O-rings for sealing sleeves for oil supply system -arrow B- and -arrow C-, lightly coating with oil. –  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft are guided centrally onto differential connecting piece. –  Align splines of right flange shaft and differential bevel gear, turning flange shaft if necessary. –  If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox.   Note Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.

–  Tighten the 4 connecting bolts -arrows- for bevel box to gearbox (only 3 are visible in figure). –  Tighten right flange shaft countersunk bolt with socket -V.A.G 1669- or commercially available 6 mm socket insert and hold against turning with drift.