Transmission, With A Sealing Cap CIRCLIP Or A Plastic Cover: Assembly

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Press the new grooved ball bearing onto the input shaft. Refer to "Grooved Ball Bearing" under: INPUT SHAFT

-- Install the input shaft -1-, output shaft for 5th/6th gears -2- together with the selector rods with selector forks -3-, the reverse gear selector fork -4- and reverse shaft -5-.

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

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Pay attention to the different bearings for the reverse gear selector fork.

Fig 2: Identifying Reverse Gear Selector Fork -1- Mounted On Axle -2- Behind 5th And 6th Gear Selector Shaft -3-

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Fig 3: Identifying Reverse Gear Selector Fork -1- Mounted On Selector Shaft With 5th And 6th Gear Selector Fork -2-

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Continuation for all Vehicles:

-- Then install the differential -1-.

Fig 4: Inserting Differential, Input Shaft & Output Shaft

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NOTE:

A 2nd technician is needed to help install the shafts into the clutch housing.

-- Hold the output shaft for 1st through 4th gear -3- and the selector shaft with selector forks -4- with the right hand.

-- Slightly lift the differential with the left hand.

-- Have the second technician lift the input shaft, the 5th/6th gear output shaft and reverse gear -2- together with the reverse shaft slightly at the same time.

-- Install the 1st to 4th gear output shaft in -direction of arrow-.

Places on the input shaft, output shafts and final drive gear/differential must engage.

-- Together with a second technician, now place the shafts and differential in their bearing seats.

-- Install the Bracket 30-211 A for the input shaft to the clutch housing.

Fig 5: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE:

The clutch housing is shown in the illustration rotated 180°.

-- Install the bolt -A- just far enough until the input shaft starts to lift.

Fig 6: Identifying Flattened Areas on Grooved Ball Bearing and Bearing Seat in Transmission Housing

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There is a flattened area on the grooved ball bearing and the bearing mount.

If the flattened areas -A and B- are present, do not insert any washers above and below the grooved ball bearing. Refer to GROOVED BALL BEARING CHANGES .
The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark the flattened side with color.

-- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see the next graphic).

-- Heat the transmission housing in the area around the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, V.A.G 1416.

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

Align the mark on the grooved ball bearing -A- with the mark on the transmission housing -B- and install the transmission housing.

Fig 7: Identifying Mark On Grooved Ball Bearing Aligned With Mark On Transmission Housing

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-- Install the transmission housing and tighten the new bolts -A, B and C- to specification.

Fig 8: Identifying Allocation Of Bolts As Replacement Parts

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If the steel bolts (outer hex head) are the replacement part, pay attention to the allocation:

A - Bolt with a permanent washer

B - Bolt without a washer

C - Bolt with a permanent washer

-- Install the grooved ball bearing/input shaft locking ring -1-.

Fig 9: Identifying Circlip & Special Tool VW 309

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-- Remove the Bracket 30-211 A from the input shaft.

-- Install the selector shaft lock sleeve all the way onto the tool. Refer to Figure.

-- Turn the transmission with the opening for the selector shaft in the assembly stand upward.

-- Install the gear shift shaft -1- into the lower bearing -2- and into the selector forks -3-.

Fig 10: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

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NOTE:

The cover is not shown in the illustration, see "Cover" in item: 2.

-- Push the gear shift shaft -1- against the retaining sleeve -2- in the -direction of the arrow- and guide is through the shift fork all the way down using the shift finger -3-.

Fig 11: Identifying Selector Shaft Pressed Against Lock Sleeve And Guided Downward With Shift Finger

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The gear shift cover -4- must be parallel to the bolting surface on the transmission housing.
It must be possible to move the gear shift shaft easily (forward and backward).

NOTE:

If the gearshift cover is at an angle to the bolting surface, then the gearshift shaft is not installed into the lower bearing.

-- Tighten the bolts -3- for the gear shift cover -4-.

Fig 12: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Install the locking screw -2-, the locking pin -arrow- must not be installed when doing so.

-- Install the backup lamp switch -F4- -1-.

-- Install the input shaft seal flush.

Fig 13: Identifying Tool To Drive-In Input Shaft Oil Seal Flush

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-- Install the slave cylinder with release bearing. Refer to CLUTCH RELEASE MECHANISM OVERVIEW .

-- Move the gear shift lever (selector lever) through all the gears.

-- Install the sealing cap as follows:

Fig 14: Identifying Input Shaft Sealing Cap Types

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-I- = metal sealing cap; secured with a circlip -A-.

-II- = plastic sealing cap; without a circlip.

Fig 15: Identifying Mounting Areas/Profiles For Sealing Caps -A- (Metal Cap) And -B- (Plastic Cap)

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Mounting Area for the Sealing Cap	Sealing Cap	Installation
-Arrow A- = vertical	Made of metal	Refer to Fig 16.
-Arrow B- = at an angle	Made of plastic	Refer to Fig 18.

Fig 16: Identifying Tool Assembly To Install Metal Cap On Transmission Housing

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-- Install the cap all the way into the transmission housing.

-- Secure the cap with the circlip -A-.

Fig 17: Identifying Transmission Housing Without Sealing Cap Circlip

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Fig 18: Identifying Tool Assembly To Install Plastic Cap On Transmission Housing

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-- Install the cap all the way into the transmission housing.

Continuation for all Vehicles:

Always pay attention to the sealing cap allocation, refer to Fig 15
Leaks in the case because of incorrect installation.
For the correct sealing cap.

-- Install the flange shafts with the springs, thrust washers and tapered rings.

Fig 19: Identifying Installation Of Flange Shaft

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