Transmission housing, shift mechanism, input shaft, output shafts (pinion shafts), differential, bevel gear transfer case and selector rods, removing and installing: Installing

Fig 1: Identifying 5th, 6th And Reverse Gear Output Shaft, Selector Rod & Reverse Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install differential - 1  -.
• Insert output shaft for 5th/6th and reverse gears - 2  - together with shift fork for reverse gear, selector rod for 5th/6th gear - 3  - and reverse shaft - 4  -.

Fig 2: Taking 1st-4th Gear Output Shaft With Selector Rods In Right Hand

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• As shown in illustration, take output shaft for 1st to 4th gears - 3  - with selector rods - 5  - in right hand.
• Lift differential slightly with left hand.
• At same time, second technician slightly lifts output shaft for 5th/6th gears and reverse gear - 2  - together with reverse shaft - 4  -.
• Insert output shaft for 1st to 4th gears in direction of arrow.

Splines of output shafts and final drive gear/differential must engage.

• Together with a second technician, displace shafts in their bearing seats.

Fig 3: Setting Input Shaft In Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set input shaft into clutch housing and swing in - arrow  -.

Fig 4: Identifying Locking Plate Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

As of transmission manufacture date 06040 

• Set securing plate - arrow  - into recess for outer race/ tapered roller bearing for input shaft.
• Tighten new bolt to specified torque

Continuation for all transmissions 

• Install transmission housing.

Fig 5: Identifying Cover Plate, Lower Selector Shaft Bearing & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install selector shaft as follows: 

• Bring selector rods into idle position.
• Install selector shaft - 1  -
• Arrange selector shaft so that shift finger is inserted into selector rods, Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:  .
• While doing this, align lower bearing - arrow  - of selector shaft through hole for cap.

• Bolt cap - A  - with an M8 x 60 mm bolt - 2  - to lower bearing for selector shaft - 1  -.

Fig 6: Identifying Cover Plate, Selector Shaft Cover & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install cap - A  - by tightening (1/2 rotation) bolts - arrows  - hand-tight on alternating sides.
• Unscrew bolt - 2  - and screw in original bolt hand-tight.
• Install shift cover - B  - for selector shaft and tighten hex bolts - 4  - to specified torque.
• Tighten hex bolts for cap.

• Insert securing bolt - 3  - for selector shaft gate with locking compound D 000 600 A2.
• Install switch for back-up lights.
• Install left flanged shaft with compression spring, thrust washer and tapered ring.
• Install Speedometer Vehicle Speed Sensor (VSS).

Fig 7: Pressing In Input Shaft Oil Seal Using T40008

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive in seal for input shaft.
• Assemble slave cylinder with release bearing.

Install bevel gear transfer case as follows:

Fig 8: Identifying O-Ring For Sealing Bevel Gear Transfer Case/Manual Transmission & O-Ring For Sealing Sleeve For Oil Supply

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Always replace and lightly oil O-ring for sealing bevel gear transfer case/manual transmission - arrow A  - and O-ring of sealing sleeve for oil supply - arrow B  - and - arrow C  -.
• Slide bevel gear transfer case completely on manual transmission and while doing this join splines of input shaft/bevel gear transfer case centrally with connecting sleeve/differential.
• Bring right axle shaft splines and differential bevel gear into alignment; rotate flanged shaft if necessary.

With proper tooth position and central guiding, the bevel gear transfer case slips up to stop against the manual transmission.

Do not pull the bevel gear transfer case against the manual transmission with the mounting bolts, otherwise the bevel gear transfer case is canted and the mounting eyelets can break off.

Fig 9: Identifying Bevel Gear Transfer Case/Manual Transmission Bolts, V.A.G 1669, V.A.G 1331 & VW 353

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten four connecting bolts (only three depicted in illustration) for bevel gear transfer case/manual transmission - arrows  -.
• Tighten conical head bolt for right flanged shaft using socket V.A.G 1669 or 6 mm socket insert, commercially available. Use a drift to secure against turning.