Assembling transmission

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If the input shaft or the transmission housing have been replaced, you must first re-determine the thickness of the input shaft circlips → Circlips for input shaft ball bearing, determining .

NOTE:

Lubricate all needle bearings with gear oil before installing.
Check synchro-rings for wear Checking synchro-ring for wear
Insert spring in selector gear Inserting spring in selector gear
Heat gear wheels, needle bearing inner races and synchronizing hubs to 130° C (max.) before pressing on (wear protective gloves).

Insert hollow shaft in bearing housing and selector fork for 1st and 2nd gear.
Place reverse gear selector gear with needle bearing, spring and synchro-ring onto hollow shaft.

The tabs on synchro-ring should engage into recesses in selector gear.

Fig 1: Pressing On Reverse Gear Synchronizing Hub

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Press on reverse gear synchronizing hub.

Installation position: high inside collar faces 3rd gear wheel.

Check axial clearance of reverse selector gear.

Fig 2: Inserting Input Shaft With Needle Roller Bearing Into Bearing Housing At An Angle Toward Rear

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Insert input shaft - A - with needle roller bearing - B - into bearing housing in direction of - arrow - at an angle toward rear.
Install reverse gear wheel and tighten 3 bolts for reverse shaft support to 30 Nm.

Fig 3: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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Slide reverse gear selector fork - C - together with locking collar - D - onto selector rod - B - and reverse gear synchronizing hub.

The markings on locking collar and synchronizing hub - arrow - must coincide.
The chamfer on locking collar faces reverse selector gear.

If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.

Fig 4: Work Surface Of Workshop Press V.A.G 1290 A Aligned So That The 3rd Hole Is Visible Above Work Surface

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Align work surface of workshop press V.A.G 1290 A so that the 3rd hole - arrow - is visible above work surface.
Place holding plate T40088/1 with sleeve T40088/2 onto work surface.
Insert bearing housing with shafts and selector rods into holding plate T40088/1.

The distance between input shaft - 1 - and thrust disc VW 412 should be approx. 210 mm, so that it is possible to perform the following work steps without changing the position of the work surface.

Fig 5: Pressing On 3rd Gear Wheel

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Press on 3rd gear wheel.

Installation position: machined side faces reverse gear synchronizing hub.

Insert circlip for 3rd gear wheel.

When replacing gear wheel or hollow shaft:

Re-determine thickness of circlip for 3rd gear wheel:

Determine thickest circlip that will just fit and install it.

The following circlips are available:

Circlip thickness (mm)
1.90	1.98	2.06
1.94	2.02	2.10

Fig 6: Pressing On Thrust Washer For 3rd Speed Selector Gear Until Limit Stop

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Press on thrust washer - A - for 3rd speed selector gear until limit stop.

Fig 7: Installing Needle Bearing For 3rd Speed Selector Gear And Circlip For 3rd Gear Needle Bearing Onto Input Shaft

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Install needle bearing for 3rd speed selector gear - 1 - and circlip - 2 - for 3rd gear needle bearing onto input shaft.
Install 3rd speed selector gear with spring and synchro-ring.

The tabs on synchro-ring should engage into recesses in selector gear.

Fig 8: Pressing On Heated Synchronizing Hub For 3rd And 4th Gear

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Press on heated synchronizing hub for 3rd and 4th gear

Installation position: high inside collar faces 3rd speed selector gear.

Fig 9: Determining Thickness Of Circlip

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Insert circlip for synchronizing hub for 3rd and 4th gear.

When replacing synchronizing hub or input shaft:

Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:

Determine thickest circlip that will just fit and install it.

The following circlips are available:

Circlip thickness (mm)
1.90	1.96	2.02
1.93	1.99	2.05

Check axial clearance of 3rd speed selector gear.

Fig 10: Pulling Pin With Clip Securing Selector Fork For 3rd And 4th Gear Out From Selector Rod

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Slide selector fork for 3rd and 4th gear - C - together with locking collar - D - onto selector rod - B - and synchronizing hub for 3rd and 4th gear.

The markings on locking collar and synchronizing hub - arrow - must coincide.

If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.

NOTE:

Do not insert pin with clip for 5th/6th gear selector fork (diameter 6 mm) into selector fork for 3rd and 4th gear.

Fig 11: Installing 4th Speed Selector Gear With Spring, Synchro-Ring, Needle Bearing And Thrust Washer For 3rd And 4th Gear And Pressing On Heated Inner Race For Needle Bearing For 5th Speed Selector Gear

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Install 4th speed selector gear - A - with spring, synchro-ring, needle bearing and thrust washer for 3rd and 4th gear - B -.
Press on heated inner race - C - for needle bearing for 5th speed selector gear.
Check axial clearance of 4th speed selector gear.

Fig 12: Pressing On 4th Gear Wheel

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Heat 4th gear wheel and press on.

Installation position: high inside collar faces 5th gear wheel.

Fig 13: Pressing On 5th Gear Wheel

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Heat 5th gear wheel and press on.

Installation position: high inside collar faces 4th gear wheel.

Place 5th speed selector gear with spring, synchro-ring and needle bearing onto input shaft.

The lugs on synchro-ring should engage into recesses in selector gear.

Fig 14: Pressing On Heated Synchronizing Hub For 5th And 6th Gear

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Install and press on heated synchronizing hub for 5th and 6th gear.
Check axial clearance of 5th speed selector gear.

Fig 15: Identifying Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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Slide selector fork for 5th and 6th gear - C - together with locking collar - D - onto synchronizing hub for 5th and 6th gear.

The markings on locking collar and synchronizing hub - arrow - must coincide.

Move selector fork for 5th and 6th gear - C - into selector rod - B -.
If the holes of selector fork and selector rod coincide, clip in pin with clip - A -.

Fig 16: Pressing On Heated Inner Race For Needle Bearing For 5th Speed Selector Gear

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Press on heated inner race for needle bearing for 5th speed selector gear.

Fig 17: Pressing On 6th Speed Selector Gear

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Install 6th speed selector gear with spring, synchro-ring, needle bearing and thrust washer for 6th gear - A -.
Heat inner race - B - for needle roller bearing and press on.
Check axial clearance of 6th speed selector gear.

Fig 18: Pressing On 6th Gear Wheel

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Install spacer sleeve - A - onto hollow shaft.
Heat 6th gear wheel and press on.

Fig 19: Circlip For 6th Gear Wheel

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Insert circlip - A - for 6th gear wheel.

When replacing gear wheel or hollow shaft:

Re-determine circlip - A - for 6th gear wheel:

Determine thickest circlip that will just fit and install it.

The following circlips are available:

Circlip thickness (mm)
1.90	2.02	2.14
1.93	2.05	2.17
1.96	2.08	2.20
1.99	2.11

Remove bearing housing from holding plate T40088/1.

Fig 20: Identifying Needle Bearing For Pinion Shaft And Hollow Shaft

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Push pinion shaft - B - with large needle bearing into hollow shaft - C - and fit small needle bearing - A -.
Prevent pinion shaft from falling out and secure on hollow shaft using e.g. a hose clip Figure.

Fig 21: Bearing Housing Secured To Transmission Housing With Two Bolts M8 And Washers

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Secure bearing housing to transmission housing with two bolts M8 (length approx. 70 mm) - arrows - and washers.
Tighten two bolts to max. 10 Nm.

NOTE:

Do not install oil collector - A - at this stage.

Fig 22: Locating Selector Rods

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Move two selector rods - arrow A - and - arrow B - to lock input shaft by selecting two gears (e.g. reverse gear and 1st gear).

Fig 23: Removing/Installing Multi-Point Socket Head Bolt For Input Shaft

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Tighten multi-point socket head bolt - 1 - for input shaft to 150 Nm.
Remove complete bearing housing from transmission housing.
Check that the two dowel sleeves for centralizing bearing housing are installed in transmission housing.
Apply sealing paste AMV 188 001 01 evenly and not too thickly onto contact surfaces between transmission housing and bearing housing.

Install bearing housing onto transmission housing.

Fig 24: Bearing Housing Secured To Transmission Housing With Two Bolts M8 And Washers

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Clip oil collector - A - into reverse shaft support.

NOTE:

Make sure that the bolts - arrows - are removed.

Remove hose clip from pinion shaft Figure.
Check that the two dowel sleeves for centralizing the transmission cover are installed in bearing housing.
Apply sealing paste AMV 188 001 02 evenly and not too thick onto contact surfaces between bearing housing and transmission cover.

Fig 25: Removing Bolts Securing Transmission Cover And Bolts Securing Bearing Housing To Transmission Housing

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Tighten securing bolts for transmission cover - A - and bearing housing - B - to transmission housing - C - to 35 Nm plus an additional 90° ¹ /₄ turn.
Lubricate new O-ring - arrow - with gear oil.

Fig 26: Torsen Differential, Spring, Pinion Shaft/Hollow Shaft, Torsen Housing And Bolts

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Place spring - 2 - and Torsen differential - 3 - onto pinion shaft/hollow shaft - 1 -.
Install Torsen housing - 5 - onto transmission cover.
Tighten bolts - 4 - to 10 Nm plus an additional 45° ¹ /₈ .

Fig 27: Installing Seal And Selector Shaft With Assembly Sleeve

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Push assembly sleeve 01E311120 - A - onto selector shaft - B -.

NOTE:

Avoid damaging oil seal - C - by only installing oil seal and selector shaft using assembly sleeve assembly sleeve 01E311120 - A -.

Move selector rods to neutral.
Install complete selector shaft.

Installation position: Chamfer of selector shaft points downward.

Fig 28: Selector Shaft Locking Bolts

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Push selector shaft - 2 - into transmission as far as it will go, simultaneously inserting pin - 3 -.

Installation position for pin - 3 - : The groove - arrow - on pin points toward selector shaft cover.

Clean bolt threads of locking fluid - 1 - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 45 Nm.

Fig 29: Selector Shaft Cover Bolts

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Install cover - A - with new O-ring.
Clean threads of bolts - arrows - with a wire brush. Then insert bolts with locking fluid AMV185101A1 and tighten to 24 Nm.

Fig 30: Location Of Rear Circlip For Input Shaft Ball Bearing

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Install rear circlip - arrow - for input shaft ball bearing.
Push ball bearing onto input shaft.

Installation position:

The sealed side of ball cage faces transmission housing.

Fig 31: Pressing In Ball Bearing

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Pressing in ball bearing:

Screw replacement stud (M8 and M10) 3114/2 into tapped hole for ball head stud.

Slide thrust plate - A - of fitting tool T10246 onto input shaft.

Position fitting tool T10246 behind splines for clutch plate. Tighten bolts - B - lightly. The bolts locate in the recess in thrust plate - A -.

Press in ball bearing onto stop by tightening bolts alternately (1/2 turn at a time).

Fig 32: Clutch Release Lever Components

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Install front circlip - D - for input shaft ball bearing.
Install dished spring - C -.

Installation position:

The curved side faces guide sleeve - B -.

Install a shrink hose onto input shaft splines.
Install guide sleeve - B - for release bearing.
Remove shrink hose.
Install clutch release lever - A - with release bearing.

Select all gears.