Volkswagen Workshop Service and Repair Manuals

Installing –  Install differential.

–  Always renew sealing rings -arrows- for output shaft bearing support.   Note The figure shows only 3 of the 4 sealing rings.

Gearbox with synchromeshed gear for reverse gear -arrow-.

–  Insert input shaft -1- and output shaft -2- together. –  Tighten nuts for output shaft bearing support to specified torque → Item. –  Set reverse gear wheel -3- on needle bearing in clutch housing. The shoulder -arrow- faces away from the clutch housing. –  Ensure that reverse shaft -4- is complete → Chapter; do not yet fit reverse shaft support to reverse shaft. –  Fit reverse shaft into clutch housing. –  Clean locking fluid from all threaded holes in reverse shaft support; a thread chaser may be used. –  Place reverse shaft support on reverse shaft.

–  Attach reverse gear selector fork -1- with support for reverse gear selector fork -2-, spring -3- and sliding piece -4-.

Installation position, reverse gear

–  Bolt on reverse gear selector mechanism -A-, tightening to specified torque → Item. –  Install selector forks -B- together with selector plates. Reverse gear support pin -C- is located in front of selector rods.

Gearbox with reverse gear locking collar -arrow-.

l  Clean locking fluid from all threaded holes in reverse shaft support; a thread chaser may be used. l  Position input shaft -1-, output shaft -2- and reverse shaft -3- on a workbench, for example, in relation to one another as shown. l  Input shaft -1- is held in position by counter-hold tool -3435-. l  Dog teeth -arrow- of reverse gear locking collar points towards synchromeshed gear for reverse gear.

–  Insert input shaft -1-, output shaft -2- and reverse shaft -3- together. Output shaft -2- contacts differential. –  Turn differential if necessary (second mechanic) so that output shaft -2- can be inserted into clutch housing. –  Tighten nuts for output shaft bearing support to specified torque → Item.

–  Install selector forks -A- together with selector plates. Reverse gear support -B- is located in front of selector rods. l  Selector rod for reverse gear engages in reverse gear locking collar -arrow-.

Continuation for all –  Screw M 8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted. –  Align selector plates.   Note The selector segments must be positioned in the grooves on the locking collars. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of clutch housing. –  Fit gearbox housing. Install reverse shaft support bolts -arrow- as follows: –  Install bolt -a-. –  Remove stud -A- (⇒ figure above).

–  Install bolt -c-. Tightening sequence: –  Tighten bolt -a- to 30 Nm. –  Tighten bolt -b- (⇒ figure below) to 25 Nm.

–  Tighten bolt -c- to 25 Nm.

–  Install pivot pin -arrow- for selector forks. Do this by aligning selector mechanism with a screwdriver so that respective pivot pin can be installed. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of cover plate. –  Fit selector shaft cover.

Install selector shaft with selector shaft cover plate as follows: –  Place selector plates in neutral. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover. –  Move selector shaft to neutral. –  Position selector shaft so that selector finger -arrow- is inserted in selector plates. –  Bolt on selector shaft cover → Item.

–  Gearboxes for vehicles with start-stop system: fit gearbox neutral position sender -G701--arrow- and tighten securing bolt to specified torque → Item.

–  Install both flange shafts with compression springs, thrust washers and tapered rings → Rep. gr. 39 „Final drive - differential“.