The stud bolts -arrows- must be vertical before installing the transmission housing

• The grooved ball bearing/input shaft only fits in one position in the transmission housing.
  Fig 1: Grooved Ball Bearing/Input Shaft Only Fits In One Position In Transmission Housing

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• 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.

-- Place a mark on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (next illustration).

-- Heat the transmission housing in the area near 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.

-- Apply sealing pasteAMV 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 2: Align Marking On Grooved Ball And Mount Transmission Housing

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-- Pay attention to the studs for the reverse gear selector shaft with selector fork. Refer to The stud bolts -arrows- must be vertical before installing the transmission housing .

• Do not distort the transmission housing when installing it; hold it parallel to the clutch housing.

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

Fig 3: Install Grooved Ball Bearing/Input Shaft Locking Ring

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-- Remove the support bridgeT10323 from the input shaft -A-.

Fig 4: Lower Input Shaft

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-- Install the transmission housing to the clutch housing and tighten the bolts to specification.

Fig 5: Bolt Together Transmission Housing And Clutch Housing

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• There are different bolts and tightening specifications, see -item 14- in TRANSMISSION HOUSING AND SHIFT UNIT .

-- Install the stub shaft -A- with the spring, thrust washer and tapered ring.

-- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold toolT10371.

-- Install the stub shaft with the spring, thrust washer and tapered ring.

-- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold toolT10371.

Install the Shift Unit as Follows:

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

-- Move the selector shafts with selector rods into the neutral position.

-- Guide the shift unit with the shift finger -1- through the selector shafts with selector rods -A and B- (selector shafts with selector rods, next illustration).

Fig 6: Install Shift Unit

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Selector shafts with selector rods -A and B-.

Fig 7: Identifying Switching Rockers

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-- Rotate the shift unit in the -direction of the arrow- far enough (→ previous illustration), until it can be guided into the transmission housing.

-- Then, rotate the shift unit in the -direction of the arrow- until the shift finger -2- points in the illustrated position.

Fig 8: Rotating Shift Unit Until Shift Finger Points In Illustrated Position

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-- Install the shift unit with the shift finger into the selector shafts with selector rods -A and B- (→ previous illustration) and at the same time all the way into the transmission housing.

• It must be possible to move the gear shift shaft easily (forward and backward).

-- Tighten the shift unit -B- bolts.

Fig 9: Identifying Backup Lamp Switch -F4- -A-, Shift Unit -B- Bolts & Nuts -C-

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-- Ignore the -arrow-.

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

-- Install the nuts -C-.

-- Install the trip recorder sensor -G75- -A- and bolt -arrow-, if equipped.

Fig 10: Identifying Trip Recorder Sensor -G75- -A- Bolt -Arrow-

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-- Install the input shaft seal. Refer to INPUT SHAFT SEAL .

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

-- Counter hold the stub shaft using the counter hold toolT10371 and tighten the bolts using the socket and extended bitT10107 A.

-- Move the transmission shift lever through all the gears.

-- Drive the cap into the transmission housing until seated using the thrust pieceT10042

Fig 11: Drive Cap Into Transmission Housing To Stop Thrust Piece T10042

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Fig 12: Secure the Sealing Cap:

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Threaded holes -arrows- near the plate:

-- Install the retainer plate -1- with the three screws.

No threaded holes in the area of the plate:

Fig 13: Identifying No Threaded Bores In Area Of Sealing Cap

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-- Install the retainer bracket -2- with the stud bolt -1-.

Installed position:

• The retaining bracket must be positioned above the center of the sealing cap.

For the correct bolts and other parts, refer to the Parts Information.