Determine thickness of circlip - 1 - and shim(s) - 2 - as follows:

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Fig 1: Determining Thickness Of Circlip And Shim(s)

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Measure a gap of 0.10 mm max. between the shim available as a replacement part and circlips, measured between shim - 2 - and inner race/tapered ball bearing - 4 -.
Check gap with a feeler gauge - 3 -.

NOTE:

When measuring, the circlip - 1 - must be fully seated in groove and inner race/tapered ball bearing - 4 - pushed in direction of - arrow -.

The following shims are available:

Shim thickness (mm) * See note
0.7	1.1	1.5
0.8	1.2	1.6
0.9	1.3
1.0	1.4

*Using shim tolerances it is possible to find the exact shim thickness required, insert two shims if necessary.

The following circlips are available:

Circlip thickness (mm)
1.70	1.80	1.90
1.75	1.85

Install determined shim(s) and circlip.

Fig 2: Sliding Torsen Differential On Hollow Shaft Splines

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Slide torsen differential on hollow shaft splines and press in direction of - arrow -.
When doing so, measure distance - a - from flat surface of outer race/tapered ball bearing - 1 - to flat surface of flange/transmission cover.

The following shims are available:

Measuring range	Adjustment shim
Measured value (mm)	Thickness (mm)
109.88 to 110.00	1.65
109.91 to 110.15	1.45
110.16 to 110.45	1.20
110.41 to 110.70	0.95
110.66 to 110.95	0.70
110.91 to 111.20	0.45

NOTE:

Turn transmission horizontally in assembly bracket.

Fig 3: Identifying Plate Spring, Torsen Housing, Determined Shim, Shim & Spring

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Place plate spring - B - in torsen housing - A -.

Plate spring installation location: The inner diameter camber faces toward flange shaft in torsen housing.

Place determined shim - C - on plate spring - B -.
Place spring - D - on flange shaft in torsen housing.
Then place torsen housing on transmission cover.

Fig 4: Identifying Transmission Cover Bolts

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Tighten bolt - arrow - to 24 Nm.

Fig 5: Installing Seal And Selector Shaft With Assembly Sleeve

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Push assembly sleeve 01E 311 120 - A - onto selector shaft - B -.

NOTE:

To prevent damage to the seal - C - , the installation of the seal and selector shaft must only be performed with the assembly sleeve 01E 311 120 - A -.
Selector rods must be in neutral position.

Install complete selector shaft.

Installation position: Flattened part of selector shaft faces downward.

Fig 6: Identifying Selector Shaft & Dowel Pin

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Slide selector shaft - A - into transmission up to stop and insert dowel pin - B - at the same time.

NOTE:

On dowel pin version with pins, pin side must be inserted into hole in transmission housing.

Fig 7: Removing/Installing Bolts And Selector Shaft Cover

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Install cover - B - with new O-ring.
Clean screw threads - arrows - with a wire brush. Then insert screws with locking compound AMV 185 101 A1 and tighten to 24 Nm.

A - Selector shaft securing bushings

Fig 8: Identifying Selector Shaft Versions

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NOTE:

Only install version - B - selector shaft securing bushings with edged collar - arrow 2 -.
On transmission with version - A - selector shaft securing bushings installed, these must always be replaced with version - B -.
If version - B - is installed, this can be reused.

Fig 9: Driving In Selector Shaft Locking Bushes Onto Stop

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Drive in selector shaft securing bushings with tube VW 421 until stop.

Fig 10: Removing/Installing Input Shaft Circlip

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Circlip - arrow - in front of grooved ball bearing of input shaft must then be installed.

Fig 11: O-Ring Remove/Install Components

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Coat new O-ring - arrow - with transmission fluid before installing in surrounding groove in transmission housing.
Pull a thin insulating hose or heat-shrinkable hose over input shaft splines.
Fill space between sealing lip and dust lip on sealing ring in guide sleeve halfway with grease G 052 128 A1 .
Lightly lubricate outer circumference of guide sleeve.

Fig 12: Identifying Bolts, Securing Plate, Guide Sleeve & Intermediate Piece

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Slide guide sleeve - 2 - over input shaft in transmission housing.
Remove insulating hose or heat-shrinkable hose.
Attach securing plate - 1 -.
Clean bolt threads - arrows - with a wire brush. Then insert bolts with locking compound AMV 185 101 A1 and tighten to 24 Nm.

Insert intermediate piece - 3 - in transmission housing.

Fig 13: Identifying Bolt, Leaf Spring & Clutch Release Lever

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You must lightly coat contact surface of clutch slave cylinder plunger with copper paste before installing clutch release lever - 3 -.
Install clutch release lever with release bearing.
Clean bolt threads - 1 - with a wire brush.
Place leaf spring - 2 - on screws - 1 -.

Then insert bolts - 1 - with locking compound AMV 185 101 A1 and tighten to 24 Nm.
Shift through all gears.