Transmission, Without A Sealing Cap CIRCLIP: Assembly

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Press the new grooved ball bearing on the input shaft, see "Grooved Ball Bearing" under: INPUT SHAFT .

-- Install the input shaft -1-, the output shaft for 5th/6th gears -2- together with the selector shaft with selector forks -3-, 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then, install the differential -1-.

Fig 2: Inserting Differential, Input Shaft & Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 shafts with selector forks -4- with the right hand.

-- Lift the differential -1- slightly 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 the -direction of the 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 3: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

With some transmissions, there are flattened sides -A- on the input shaft grooved ball bearing and on the bearing mount -B-.

Fig 4: Identifying Flattened Areas on Grooved Ball Bearing and Bearing Seat in Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Check the input shaft grooved ball bearing and the transmission housing.

Input Shaft Grooved Ball Bearing and Transmission Housing
No flattened sides on the grooved ball bearing -A- and bearing mount -B-, refer to FROM TRANSMISSION BUILD DATE 10 APRIL 2006 THROUGH APPROXIMATELY 21 JANUARY 2008 .
Flattened sides on the grooved ball bearing -A- and bearing mount -B-, refer to Figure