Assemble locking collar and reverse gear selector gear

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Fig 1: Assembling Locking Collar And Reverse Gear Selector Gear

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Gear wheel for reverse gear
Locking collar
Thrust piece

Slide locking collar over reverse gear selector gear.

Installation position:

Pointed teeth - arrow A - in locking collar point opposite reverse gear selector gear drive splines - arrow B -.
Thrust piece notches - 3 - in reverse gear selector gear - arrow C - and locking collar - arrow D - must align.

Then place thrust piece in reverse gear selector gear notches and press thrust piece in locking collar notches.

Fig 2: Placing 1st Gear Selector Gear With Needle Bearing And Synchronizer Rings On Inner Race/Needle Bearing

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Then place 1st gear selector gear - C - with needle bearing and synchronizer rings on inner race/needle bearing.
Place thrust washer for 1st gear and reverse gear on hollow shaft.
Attach reverse gear selector gear - A - (with locking collar mounted) together with reverse gear selector rod - B -.

Fig 3: Placing Reverse Shaft With Notch On Tab On Reverse Shaft Mount

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Place reverse shaft - 1 - with notch - arrow A - on tab - arrow B - on reverse shaft mount - 2 -.

Fig 4: Identifying Reverse Gear, Clutch Hub & Magnet

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Place reverse gear - 1 - with needle bearing in reverse shaft, when doing so, reverse gear splines must face toward reverse gear selector gear.
Place clutch hub - 2 - with needle bearing and synchronizer rings on hollow shaft.
Place magnet - 3 - in transmission housing rib.

Fig 5: Driving On Selector Rod Securing Bushings With Tube VW 421 To Stop

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Bring selector rods into neutral position - arrow -.
Drive on selector rod securing bushings - 1 - to - 4 - with tube VW 421 to stop.

NOTE:

Do not interchange securing bushings for selector rods and selector shaft.

Check whether or not there are 2 alignment pins in transmission cover for centering transmission cover/housing.
Apply sealing paste AMV 188 001 02 evenly and not to thick on transmission housing joint surfaces at transmission cover.

Fig 6: Identifying Bolts For Securing Bearing Bracket, Bolt For Securing Reverse Shaft, Connection Screws & O-Ring

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Place transmission cover - B - on transmission housing. Do not screw in screws - A - yet.
Hand-tighten bolt - arrow 2 - in reverse shaft.
Hand-tighten new bolts - arrow 1 - in bearing bracket.
Then tighten the 13 bolts - A - to 24 Nm.

Then tighten bolts - arrows 1 - to 27 Nm and bolt - arrow 2 - to 24 Nm.
Coat new O-ring - C - with transmission fluid and insert in surrounding groove in transmission cover.
Then rotate transmission horizontally in assembly bracket.

Fig 7: Securing Hollow Shaft By Moving Selector Rods

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Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.

Fig 8: Locating Twelve-Point Nut On Hollow Shaft

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Then tighten twelve-point nut hollow shaft to 75 Nm.

A - Torque wrench

Then shift selector rods into neutral position.
Turn transmission in assembly bracket with transmission cover upward.

Fig 9: Removing Circlip, Shim(S), Inner Race, Outer Race & Spacer Ring

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Place spacer ring - 5 - on hollow shaft twelve-point nut.
Install inner race - 4 - and outer race - 3 -. These components are push fit and can be removed by hand.

If you have replaced the drive pinion (gear set), you must redetermine the thickness of the circlip - 1 - and shim(s) - 2 - for tapered roller bearing on drive pinion → Determine thickness of circlip and shim(s) as follows: .