From Transmission Build Date 10 April 2006 Through Approximately 21 January 2008

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One washer each is inserted above and below the input shaft grooved ball bearing INPUT SHAFT => List Item:Grooved Ball Bearing .

Upper washer	Outer circumference	78.6 mm
Lower washer	Outer circumference	85 mm

Fig 1: Identifying Measurement Of Shoulder Above Grooved Ball Bearing Mount

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Shoulder Above the Grooved Ball Bearing	Dimension "a"	Upper Washer
Through transmission build date 4 April 2006	10 mm	no
From transmission build date 10 April 2006	10.7 mm	yes

Fig 2: Identifying Bearing Seat

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Area Below the Bearing Seat		Lower Washer
Through transmission build date 9 April 2006	not deeper	no
From transmission build date 10 April 2006	slightly deeper	yes

-- Place a washer (85 mm outer circumference) -1- on the grooved ball bearing -2-.

Fig 3: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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

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Flattened areas -A- on the input shaft grooved ball bearing and bearing mount -B-.

Do not place any washers above and below the grooved ball bearing.
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.

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

Fig 5: Identifying Mark On Grooved Ball Bearing Aligned With Mark On Transmission Housing

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

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

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

Fig 6: 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

-- If a washer was mounted on the grooved ball bearing before installation, then a washer -1- (outer diameter = 78.6 mm) must be installed after installation -2-. Refer to FROM TRANSMISSION BUILD DATE 10 APRIL 2006 THROUGH APPROXIMATELY 21 JANUARY 2008 .

Fig 7: Identifying Laying Washer Above Grooved Ball Bearing

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

Fig 8: Identifying Circlip & Special Tool VW 309

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

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

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

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

Fig 9: 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 selector fork all the way down using the shift finger -3-.

Fig 10: 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 gear shift cover is at an angle to the bolting surface, then the gear shift shaft is not installed into the lower bearing.

-- Tighten the bolts -3- on the gear shift shaft cover -4-.

Fig 11: 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 left and right flange shafts, the pressure springs, the thrust washers and the tapered rings.

-- Install the input shaft seal.

Fig 12: Identifying Tool To Drive-In Input Shaft Oil Seal Flush

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-- Install the slave cylinder with release bearing and tighten the bolts -arrows- to specification, see "Bolt" under: CLUTCH RELEASE MECHANISM OVERVIEW .

Fig 13: Identifying Slave Cylinder With Release Bearing

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

-- Drive the cap into the transmission housing to the stop using the thrust piece T10042

Fig 14: Identifying Thrust Piece T10042 To Drive Cap Into Transmission Housing To Stop

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