Install The Gear Carrier On The Transmission Cover As Follows:

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Fig 1: Identifying Center Differential Housing

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Installed position: the tab -arrow A- on the gear carrier -2- must installed into the opening -arrow B- inside the transmission cover.

-- Install the oil catch tray -1-.

-- Mount the spacer sleeve -3- and the adjusting shim -4- (for positioning the center differential) on the output shaft.

-- Slide the center differential -2- all the way in direction of the gear carrier -1-.

Fig 2: Place Center Differential On The Transmission

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-- Insert the plate spring -5-, the adjustment shim(s) -4- and the spring -3- in the center differential housing -6-.

Plate spring installed position -5- : the inner diameter with it camber -arrow- faces the center differential housing -6-.

-- Apply sealing paste AMV 188 001 02 evenly and not too thick.

-- Then position the center differential housing -6- on the transmission.

-- Press the center differential housing -C- on until it makes contact with the transmission cover and hold it securely.

Fig 3: Attaching Center Differential Housing To Transmission Cover Using The Bolts

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-- Install the new bolts -A-, -B- and -arrows- and tighten them to the tightening specification.

NOTE:

Not all versions have the double bolts -B- ; allocation, Bolts are installed in place of the double bolts -2- CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW .

-- Install the new O-ring on the cover -2-.

Fig 4: Installing T40216 On Selector Shaft

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-- Install the T40216 on the selector shaft -1-.

-- Insert the selector shaft in the transmission -arrow A- by raising it slightly -arrow B-.

Fig 5: Installing Gearshift Shaft Into Transmission And Lift It Slightly

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-- Bring the selector shaft cover -2- into contact with the transmission housing.

Fig 6: Remove Bolts And Pry Selector Shaft Cover Off Carefully

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-- Tighten the new bolts -1- to the tightening specification.

-- Remove T40216.

-- If equipped, install the transmission neutral position sensor -G701- -A- with a new O-ring in the gearshift shaft cover -B-.

Fig 7: If Equipped, Remove Transmission Neutral Position Sensor -G701-

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-- Tighten new bolt -1- to the tightening specification.

-- Install the guide sleeve -6- and the locking plate -5-, if equipped.

Fig 8: Identifying Clutch Release Lever Components

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-- Clean bolt threads -4- with a wire brush. Then install and tighten the bolts with locking fluidAMV 185 101 A1 to the tightening specification -6- CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW => Bolt .

CAUTION:

Noises when actuating the clutch

Rattling noises can occur when pressing the clutch if there is not enough grease on the release bearings.
Lubricate the release bearings with adhesive lubricating paste G 000 150. Refer to CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW .
Remove any grease still in the guide sleeve bearing area.

-- Install the clutch release lever -1- together with the release bearing -2- and the spring -3-. Refer to CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW .

CAUTION:

Check which version of the needle bearing is inside the dual mass flywheel.

Needle bearings is missing the 4th roller -arrows- must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to DUAL MASS FLYWHEEL NEEDLE BEARING, SACHS AND LUK .
New needle bearings are equipped with rollers.
On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!

Fig 9: Checking Needle Bearing Inside Dual Mass Flywheel

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-- Install the clutch module and the left flange shaft INSTALL THE CLUTCH MODULE .

-- Fill the transmission with transmission fluid and check the level. Refer to GENERAL INFORMATION . Remove the oil filler plug -arrow-.

Fig 10: Removing Oil Filler Plug

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