Disassembly And Assembly: Transmission: Assembling: Notes

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NOTE:

The adjusting shim used for pre-loading the bearing on the impeller wheel/drive gear's tapered roller bearing must be determined again whenever replacing the transmission cover, the impeller wheel/drive gear, its tapered roller bearing, the bearing shield or the center differential housing. Refer to DRIVE WHEEL/SPUR GEAR TAPERED ROLLER BEARING PRE-LOAD, DETERMINING .

Use an assembly tool as follows to keep the synchronization for the reverse gear from sliding apart when installing the shift shaft package:

-- Install an extracting hook from the 3349 on the T40041, as shown in the illustration.

Fig 1: Installing Extracting Hook From 3349 On T40041

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-- Next, position the assembly tool and the extraction hook on the reverse gear synchronizer hub -A- and on the third gear wheel -C- and tighten it down.

The threaded spindle must not protrude past the T40041 on the extraction hook -arrow-.
The assembly tool must be positioned within the radius of the transmission support -D-.

-- Use some grease to attach the thrust washer -B- onto the reverse gear synchronizer hub -A-.

-- Mount the 3116 on the output shaft.

Fig 2: Mounting 3116 On Output Shaft

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-- Attach the mounts T40214/1 and T40214/2 to the transmission housing using the bolts -1- (6 in all), as illustrated.

-- Install the plate T40213/1 using the bolts -2- on the mounts T40214/1 and T40214/2.

-- Turn the spindle -3- back until it hits the end stop and position the spindle -4- in the center.

-- Turn the transmission housing with the attached special tools in the assembly stands horizontally, as shown in the illustration.

-- Heat up the ball bearing in the transmission housing using a V.A.G 1416.

-- First, guide the shift shaft package -5- underneath the plate T40213/1 in the direction of -arrow A-.

-- Next, install the shift shaft package and the driveshaft in the transmission housing in direction of -arrow B-.

-- Keep the shift shaft package in this position and attach both of the spindles T40213/2 to the shafts. The gearshift rails -6- must be aligned with the bearing areas in the transmission housing.

NOTE:

Due to the clearance the ball bearings have in the shift shaft package, the shift shaft package for some transmissions can be pressed all the way into the transmission housing by hand.

-- After doing this, turn the transmission in the assembly bracket and the shift shaft package so that they face up.

Fig 3: Identifying Transmission Special Tool Assembly Setup

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-- If necessary, align the spindles T40213/2 with the shafts again so that the spindles press in the center of the shafts.

CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be installed together.
It is permissible to install the shaft alternating from side to side by turning each spindle maximum one turn.

-- Then install the input and output shafts all the way into the ball bearing by turning the spindles T40213/2 one turn alternating from side to side.

NOTE:

Don't tilt the shafts when pressing them in. Guide the shift rails into their bearing areas in the transmission housing.
Remove the T40041 before fastening the extraction hook on the housing rib -arrow-.
Pay special attention to synchronizing the reverse gear! The intermediate ring tabs must lock in the reverse gear synchronizer hub!

-- Remove the T40213 and the T40214.

-- Install the magnet -4- and the oil guide element -5- in the transmission housing.

Fig 4: Identifying Transmission Housing Components

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-- Position the oil catch tray -2- on the pins -arrow B- located on the bearing support -3- and then clip them onto the bearing support -arrows A-.

-- Install the reverse drive gear and the reverse shaft -1-, while also aligning the threaded opening -arrow C- with the locating bore -arrow D- for the clutch slave cylinder.

-- Check whether there are 2 alignment pins for centering the transmission cover/transmission housing in the transmission housing or transmission cover.

-- Apply sealing paste AMV 188 001 02 evenly and not to thick on transmission housing joint surfaces at transmission cover.

-- Place the transmission cover -D- on the transmission housing -E- ; don't -C- install bolts yet.

Fig 5: Identifying Transmission Cover Bolts

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-- Hand tighten the bolt -B- into the reverse shaft.

-- Clean bolt threads -A- with a wire brush. Install the bolts with locking fluid AMV 185 101 A1 and hand-tighten them into the bearing bracket.

-- Tighten the bolts -C- using the specified torque.

-- Then tighten the bolts -A- and -B- to the specified torque.

-- Place the shim -2- on the input shaft.

Fig 6: Identifying Input Shaft Ball Bearing Locking Ring

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