Volkswagen Workshop Service and Repair Manuals

Installing   Note t  Press bearing mounting with deep groove ball bearing onto input shaft and output shaft → Fig.. t  Press needle roller bearing sleeve for synchromeshed gear for 5th gear onto input shaft → Fig..

–  Position assembled components, input shaft -2- and output shaft -1- with bearing mounting for deep groove ball bearing, in thrust piece -T10085-. –  Insert selector mechanism (selector forks) -4- in the shaft locking collars. –  Install reverse gear shaft -3- with reverse gear.

–  Screw guide pin -T10079- onto stud (secures reverse gear) -arrow-. –  Insert components together into gearbox while guiding guide pin -T10079- through hole to secure selector mechanism in gearbox housing. –  Remove guide pin -T10079-. Note the following before pressing in: t  Correct engagement of selector forks in locking collars.

t  Check dimension -a- of output shaft splines.   Note t  Due to different spline heights, dimension -a-, output shafts of individual gearboxes have different lengths. t  To ensure that output shaft and input shaft are always pressed in evenly, it may be necessary to place a shim -T10083/1- (thickness 3 mm) onto input shaft. t  Therefore, measure dimension -a- of output shaft splines.

Dimension -a- = 30.6 mm

Placing shim -T10083/1- onto input shaft → Fig.

Place shim -T10083/1- onto input shaft and carefully press in bearing mounting together with input shaft and output shaft to stop

Carefully press in bearing mounting together with input shaft and output shaft to stop

–  Install bolt -A- for securing reverse gear wheel shaft. –  Install pivot pin -B- in bottom of gearbox.

–  Install reversing light switch -C-. –  Install pivot pin -B- in top of gearbox. –  Place selector plates in neutral. –  Apply sealant -AMV 188 200 03- evenly to sealing surface of selector mechanism cover. –  Install selector shaft with selector cover -A-. Then tighten bolts -arrows-.

–  Using new bolts -A-, tighten bearing mounting for input and output shafts.   Note Tighten bolts to specified torque, working from centre outwards using alternate sequence. –  Tighten hexagon flange nut -B- for securing selector mechanism (selector forks).

–  Then insert oil collector -A- in notch -1- and in hole -2- of gearbox housing.

–  Now insert oil guide -B- into gearbox housing. –  The magnet is inserted into the oil guide -B-.

–  Install differential -A-. –  Apply sealant -AMV 188 200 03- evenly to sealing surface. –  Secure clutch housing to gearbox housing. –  Turn gearbox in support bracket so that gearbox housing is upwards.

–  Install gear wheel for 5th gear -1-. Installation position of gear wheel for 5th gear: The high shoulder -arrow- faces gearbox housing cover. –  Install 5th gear synchromeshed gear with needle bearing. –  Place 5th gear synchro-ring on synchromeshed gear. –  Install 5th gear synchro-hub complete with locking collar and stop ring.

–  Insert 5th gear selector fork -2- and push in pivot pin -1- to stop in -direction of arrow-. –  Determine new retaining ring -arrow-. –  Determine thickest possible retaining rings which will still fit for input shaft -3- and output shaft -4- and install them. Available retaining rings → Electronic parts catalogue (ETKA)

Thickness (mm)
2.00	2.10
2.20

–  Tighten gearbox housing cover.

–  Install both flange shafts with springs, thrust washers and tapered rings. –  Install clutch release lever together with release bearing and guide sleeve → Fig..