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

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Inserting Input Shaft, Output Shaft For 5Th/6Th Gears Together With Selector Rod, Shift Fork And Reverse Shaft

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

Fig 2: Inserting Differential, Input Shaft & Output Shaft

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

Insert output shaft for 1st to 4th gears in direction of - arrow -.

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

Together with second technician, displace shafts and differential in their bearing seats.

Fig 3: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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Secure bracket 30 - 211 A for input shaft on clutch housing.

NOTE:

For the sake of illustration, clutch housing is depicted rotated 180 °.

Screw in bolt - A - far enough until input shaft rises slightly.
Heat transmission housing using Hot air gun , e.g. V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to 100 ° C for approx. 10 minutes.
Install transmission housing.

Fig 4: Identifying Circlip & Special Tool VW 309

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Install circlip - 1 - for grooved ball bearing/input shaft.
Remove bracket 30 - 211 A for input shaft.

Fig 5: Identifying Drift T10168 & Special Tool VW 353

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If lock sleeve for selector shaft has been removed, drive it in now using drift T10168 until tool makes contact.
Turn transmission with opening for selector shaft in assembly stand upward.

Fig 6: Inserting Selector Shaft Into Lower Bearing And Into Shift Forks

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Insert selector shaft - 1 - into lower bearing - 2 - and into shift forks - 3 -.

NOTE:

The cap is removed in the illustration for reasons of clarity.

Fig 7: Pressing Selector Shaft Against Lock Sleeve And Guide Downward With Shift Finger

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Press selector shaft - 1 - against lock sleeve - 2 - in direction of - arrow - and guide downward with shift finger - 3 - through shift forks up to stop.

Shift cover - 4 - must stand parallel to bolting surface on transmission housing during this operation.

NOTE:

If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.
Selector shaft must be able to be moved slightly in selector motion (up- and downward).

Fig 8: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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Tighten bolts - 3 - for cover/selector shaft - 4 -.
Install mounting screw - 2 -. Lock elbow - arrow - must lie outside.
Install switch for back-up lights - 1 -.
Install flanged shaft and stub shaft with compression springs, thrust washers and tapered rings.

Fig 9: Pressing In Input Shaft Oil Seal Using T40008

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Drive in seal for input shaft.
Install slave cylinder with release bearing.
Shift through all gears.

Fig 10: Driving Cap Into Transmission Housing To Stop Of Thrust Piece T10042

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Drive cap into transmission housing to stop of thrust piece T10042

Install bevel gear transfer case as follows:

Fig 11: Identifying O-Ring For Sealing Bevel Gear Transfer Case/Manual Transmission & O-Ring For Sealing Sleeve For Oil Supply

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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 by joining 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.

NOTE:

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

Fig 12: Identifying Bevel Gear Transfer Case/Manual Transmission Bolts, V.A.G 1669, V.A.G 1331 & VW 353

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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 prevent turning.