AWD Vehicles

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-- Remove the circlip -arrow-.

-- Remove the bearing inner race -item 25- OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL => List Item: Bearing Inner Race or -item 30- OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL => List Item: Bearing Inner Race -arrow- using the : VAS251001 and Seal Installer - Shaft Seal: T10431/1 .

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Vehicles without Self-Locking Center Differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the : T40413/7 -1-.

-- Bolt the : T40413/7 with the : T40213A .

-- Tighten the : T40213A in the vise or on the : T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The gear set is secured with the : T40155 and : 10-222A/12 on the : VAS6100 .
The bolts from the : T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 -

Extracting Tool - Adapter: T40413/7

4 -

Assembly Tool: T40213A

5 -

Extracting Tool - Adapter: T40413/8

6 -

Extracting Tool - Nut: T40213/3

-- Switch the Gearshift Rail/Shift Fork for 4th and 6th Gear -1-, Gearshift Rail/Shift Fork for 5th and 7th Gear -2- and Gearshift Rail/Shift Fork for 1st and 3rd Gear -3- in the direction of -arrows-.

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-- Warm the bolt -arrow- to approximately 100 °C (212 °F).

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Tip:

The bolt from the output shaft has a very high loosening torque.

-- Remove the bolt -arrow- with the : T10162A -1-.

If when warning the bolt the oil pipe -2- in the output shaft is damaged it must be replaced.

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-- Drive out the oil pipe -2- using the Valve Guide/Clutch Release Push Rod Seal Drift: 10-206 -1- from the output shaft in the direction of -arrow-.

-- Drive in the new oil pipe on the opposite side again.

-- Then shift all gears into the transmission neutral position.

Continuation for All Vehicles

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-- Remove the bolt -arrow- and remove the shift forks for 4/6 gear and 5/7 gear together.

-- Remove the input shaft 1 from the gear set.

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CAUTION:

Damage to input shaft 1

When removing the input shaft 1, the 7th gear wheel may already be loosened and can fall.

-- Shift fork the gearshift rail/shift fork for 1st and 3rd gear -1- and gearshift rail/shift fork for 2nd gear and reverse gear -2- upward in the direction of -arrow-.

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Vehicles with Self-Locking Center Differential

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-- Remove the circlip -1- from the outer output shaft -2-.

Screw in the Thrust Piece: T10205/13 in the Hydraulic Cylinder: VAS6178 .

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Press on the 4th Gear 1, Vehicles with Self-Locking Center Differential

Fig 1: Press on the 4th Gear -1-, Vehicles with Self-Locking Center Differential

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2 -

Press Piece - Multiple Use: 30-11

3 -

Press Piece - 31.5mm: VW418A

4 -

Extracting Tool - Screwdriver Bit: T40413/2

5 -

Hydraulic Press: VAS6178

6 -

Extracting Tool - Puller: T40413/1

Vehicles without Self-Locking Center Differential

Drive Wheel for Spur Gear 1 and Drive Wheel Roller Bearing Inner Race 2

Fig 2: Drive Wheel for Spur Gear -1- and Drive Wheel Roller Bearing Inner Race -2-

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3 -

Press Piece - Multiple Use: VW426

4 -

Extracting Tool - Screwdriver Bit: T40413/2

5 -

Extracting Tool - Puller: T40413/1

6 -

Hydraulic Press: VAS6178

-- Remove the spacer sleeve -item 4- OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL => List Item: Spacer Sleeve.

Press on the 4th Gear 1, vehicles without Self-Locking Center Differential

Fig 3: Press on the 4th Gear -1-, vehicles without Self-Locking Center Differential

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2 -

Extracting Tool - Screwdriver Bit: T40413/2

3 -

Hydraulic Press: VAS6178

4 -

Extracting Tool - Puller: T40413/1

Continuation for All Vehicles

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-- Remove the circlip -2- for the drive axle 2 -1-.

Align the Drive Axle 2 1

Fig 4: Align the Drive Axle 2 -1-

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CAUTION:

Risk of destroying the gears, shaft and bearing bracket.

To press out the input shaft 2, align as follows.
The bevel -arrow- of the drive axle 2 -1- must be located on the side of the intermediate sprocket for the reverse gear -2-.

Press Out the Drive Axle 2 1, Vehicles without Self-Locking Center Differential

Fig 5: Press Out the Drive Axle 2 -1-, Vehicles without Self-Locking Center Differential

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2 -

Bearing Installer - Multiple Use: 32-111

3 -

Press Piece - Rod: VW407

4 -

Bearing Installer - Bearing Press Plate: T10084A

5 -

Press Plate: VW401

6 -

Press Plate: VW402

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate: T10084A -arrow-.

Press Out the Drive Axle 2 1, Vehicles with Self-Locking Center Differential

Fig 6: Press Out the Drive Axle 2 -1-, Vehicles with Self-Locking Center Differential

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2 -

Press Piece - Multiple Use: 40-105

3 -

Press Piece - Rod: VW408A

4 -

Press Piece - Multiple Use: VW519

5 -

Exhaust Pipe Wedge Set: 3140A/1

6 -

Press Plate: VW402

7 -

Press Plate: VW401

8 -

Bearing Installer - Bearing Press Plate: T10084A

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate: T10084A -arrow-.

Continuation for All Vehicles

Depending on the servicing in the next work procedure:

Input Shaft 2, Disassembling and Assembling. Refer to INPUT SHAFT 2, DISASSEMBLING AND ASSEMBLING .
Input Shaft 1, Disassembling and Assembling. Refer to INPUT SHAFT 1, DISASSEMBLING AND ASSEMBLING .
Output Shaft, Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING
Vehicles with self-locking center differential: inner output shaft disassembling and assembling. Refer to INNER OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING, ONLY VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .

Assembling

Insert the Input Shaft 2 2 in the Bearing Bracket

Fig 7: Insert the Input Shaft 2 -2- in the Bearing Bracket

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Warm the bearing for the output shaft -1- using the Hot Air Gun: VAG1416 .
The bevel -arrow- of the output shaft 2 must be located on the side of the intermediate sprocket for the reverse gear -3-.

Press in the input shaft 2 2 in the Bearing Bracket 3

Fig 8: Press in the input shaft 2 -2- in the Bearing Bracket -3-

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When pressing in the input shaft 2 pay attention to the splines -arrows-.

1 -

Press Piece - Multiple Use: VW412

4 -

Extracting Tool - Sleeve: T40413/10

-- Determine and insert the thickest circlip -2- - which can still just be installed - for the drive axle 2 -1-.

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The following circlips are available. Refer to the Parts Information for the part number.

Circlip Thickness (mm)
2.41	2.49	2.57
2.45	2.53

4th Gear 1, Installing

Fig 9: 4th Gear -1-, Installing

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3 -

Bearing Installer - Differential Bearing: 40-21

Warm the 4th gear -1- using the Inductive Heater: VAS6414 to 120 °C (248 °F).
When pressing on the splines -arrow- pay attention to the 4th gear -1- and the gear assembly for the 4th gear -2-.
Vehicles with self-locking center differential: insert the circlip -item 9- OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL => List Item: Circlip

Vehicles without Self-Locking Center Differential

Drive Wheel for Spur Gear 2, Pressing on

Fig 10: Drive Wheel for Spur Gear -2-, Pressing on

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3 -

Bearing Installer - Differential Bearing: 40-21

Position the spacer sleeve -1- beforehand.
Warm the drive wheel for spur gear -2- to 120 °C (248 °F) using the Inductive Heater: VAS6414 .
The groove on the drive wheel of the spur gear points to the Bearing Installer - Differential Bearing: 40-21 .

Press on the Output Shaft Roller Bearing Inner Race 1

Fig 11: Press on the Output Shaft Roller Bearing Inner Race -1-

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1 -

Press Piece - Trailing Arm: 2010

Warm the output shaft roller bearing inner race -1- using the Inductive Heater: VAS6414 to 120 °C (248 °F).
Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Trailing Arm: 2010 -2-.

Continuation for All Vehicles

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-- Carefully guide the input shaft 1 into the gear set -arrow-. While doing so, make sure the needle bearings -A and B- are installed correctly.

-- Position the shift forks and secure with the bolt -arrow-.

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The following procedure is only necessary after disassembling the output shaft.

-- Press in the locking sleeve for the gearshift rail/shift fork 1st and 3rd gear -A- and the locking sleeve for the gearshift rail/shift fork 2nd and reverse gear -B-. Refer to Figure.

Fig 12: Press in the New Retaining Sleeves -A, B, C and D-

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Vehicles without Self-Locking Center Differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the Extracting Tool - Adapters: T40413/7 -1-.

-- Bolt the Extracting Tool - Adapter: T40413/7 with the Gearbox Assembly Tool: T40213A .

-- Tighten the Gearbox Assembly Tool: T40213A in the vise or on the Gearbox Support: T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The bolts from the Extracting Tool - Adapter: T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 -

Extracting Tool - Adapter: T40413/7

4 -

Assembly Tool: T40213A

5 -

Extracting Tool - Adapter: T40413/8

6 -

Extracting Tool - Nut: T40213/3

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-- Clean the internal threads of the output shaft with a thread tap.

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-- Install the new bolt -arrow- using the : T10162A -1- and tighten.

-- Then shift all gears into the transmission neutral position.

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-- Warm the bearing inner race -item 25- OVERVIEW - OUTPUT SHAFT, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL => List Item: Bearing Inner Race or -item 30- OVERVIEW - OUTPUT SHAFT, VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL => List Item: Bearing Inner Race with a Inductive Heater: VAS6414 and push with the shoulder downward -arrow A- all the way.

-- Install the circlip -arrow-

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-- Install the oil pan -item 5- OVERVIEW - GEAR SET, VEHICLES WITHOUT SELF-LOCKING CENTER DIFFERENTIAL => List Item: Oil Pan.

-- Install the gear set. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

Tightening Specifications

Refer to OVERVIEW - BEARING BRACKET
Refer to OVERVIEW - OUTPUT SHAFT