General repair instructions

To make sure of satisfactory and successful transmission repairs the maximum care and cleanliness and proper tools are essential. When carrying out vehicle repairs basic safety precautions apply.

A number of general instructions for individual repair operations, which are otherwise mentioned at various points in the article, are summarized here. They apply to this article.

Special tools 

For a complete list of special tools used in this article

Refer to Booklet; Special tools, Workshop equipment

Transmission 

• Select the correct bolts and other components according to the transmission code letters. Refer to Code letters, application, ratios, capacities .
• When installing a new transmission, the oil level must be checked and oil added. Refer to Oil level in manual transmission, checking .
• Capacities and specifications. Refer to Code letters, application, ratios, capacities .
• Carefully clean all joints and adjacent areas before disconnecting.

• When installing transmission, make sure that the dowel sleeves are installed correctly.

Sealants 

• Thoroughly clean housing joint surfaces before applying sealing paste.
• Apply sealing paste AMV 188 001 02 evenly and not too thick.
• Breather holes must remain free of sealing paste.

O-rings, seals, gaskets 

• Always replace O-rings, seals and gaskets.
• Always inspect the contact surface on the housing or shaft for burrs or other signs of damage resulting from removal of gaskets and seals.
• Thoroughly clean housing joint surfaces before assembling.

Fig 1: Identifying Space Between Oil Seal Sealing Lips

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Before installing radial shaft oil seals, lubricate outer diameter slightly and half fill space between sealing lips -arrow- with sealing grease G 052 128 A1.
• Open side of the seal faces toward the side containing the oil.
• When replacing oil seals, the point at which the sealing lips make contact vary (use insertion depth tolerances).
• Lightly lubricate O-rings before installing. This prevents them from being damaged when assembling.

• Check oil level in transmission after replacing seals and gaskets. Refer to Oil level in manual transmission, checking .

Locking elements 

• Do not over-stretch circlips.
• Always replace circlips which been damaged or over-tightened.
• Circlips must be seated in the base of the groove.

Fig 2: Identifying Locking Elements

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace spring sleeves. Installation position: Slot -A- longitudinal to line of force -arrow-.

Nuts, bolts 

• Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
• Tighten and loosen nuts and bolts for securing covers and housings in a diagonal sequence.
• Take care not to tilt particularly sensitive components, such as clutch pressure plates, loosen and tighten nuts and bolts gradually in a diagonal sequence.
• The tightening torques stated apply to non-oiled nuts and bolts.

• Always replace self-locking nuts and bolts.
• Clean threads of bolts using a wire brush with a locking compound screw in. Then apply AMV 185 101 A1 when inserting.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Bearings 

• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing toward the drift or other tool used for installing.
• Mark the needle roller bearings on 1st to 5th speed sliding gears when removing. Make sure the needle roller bearings are in the same position when re-installing.
• Grease needle roller bearing for transmission input shaft in flywheel.
• Lubricate all bearings in transmission housing with gear oil before installing.

• Heat inner races of tapered roller bearings to approx. 100 ° C before installing. Press fully up to stop free of axial play when installing.
• Do not interchange the outer or inner races of bearings of the same size. The bearings are paired.
• Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.
• The tapered roller bearings for the output shaft and the differential in the transmission are low-friction bearings. Do not add oil to new tapered roller bearings when measuring friction torque. The bearings are pre-treated at the factory with a special type of oil for this purpose.

Shims 

• Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain exact shim thickness required.
• Check for burrs and damage. Install shims which are in perfect condition.

Sliding gears 

• After installing, check that 1st to 5th speed sliding gears have axial play of 0.15... 0.35 mm and move freely.

Synchronizer rings 

• Do not interchange synchronizer rings. When reusing always install the same gear.
• Check for wear, replace if necessary.
• Coat with gear oil when installing.

Gears, synchro-hubs, inner races for sliding gears 

• Heat gears and synchro-hubs to approx. 100 ° C before installing. When installing press fully up to stop free of axial play.
• Heat inner races for sliding gears to approx. 100 ° C when installing.
• Temperature can be checked with temperature tester V.A.G 1558.
• Note installation position.

Clutch mechanism 

• When removing transmission, remove clutch slave cylinder without disconnecting pipes.
• Do not depress the clutch pedal after removing the slave cylinder if the hydraulic line is still connected. Otherwise the piston will be pressed out of the slave cylinder.
• Make sure clutch pressure plate is kept straight; loosen and tighten bolts gradually in diagonal sequence.
• To reduce the odor of the burnt clutch, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission.