General Information: Components
WARNING: This page is about a different car, the 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.
Transmission
- Make sure that the alignment sleeves between the engine and transmission are positioned correctly when installing the transmission.
- Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.
- For the correct bolt allocation, refer to the appropriate Service Information.
- For the correct transmission fluid specification, refer to Maintenance, Diagnosis , Maintenance, Diagnosis , Maintenance, Diagnosis .
- Fill the transmission fluid after repairing the manual transmission.
Sealant
- Clean the housing separating surfaces thoroughly before applying the sealant.
- Apply the sealing paste AMV 188 200 03 evenly and not too thick.
Gaskets, Seals and O-Rings
- Replace the gaskets, seals and O-rings.
- After removing gaskets and seals, always inspect the contact surfaces on the housing or shaft for burrs resulting from removal, or for other signs of damage.
- Before installing the seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with Grease G 052 128 A1.
- The open side of the seal point toward the fluid to be sealed in.
- Press in the new seal, so that the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
- Lightly lubricate O-rings before installing them in order to prevent them from being crushed when inserting.
- After replacing the seals and O-rings, check the transmission fluid level and fill as necessary, refer to TRANSMISSION FLUID, CHECKING AND REPLACEMENT .
Retainers
- Do not overstretch the circlip.
- Installed position for some of the circlips: The circlip is narrower on top and this shape matches its installed location. This makes it easier for the pliers to grab the circlip when removing and installing it.
- Always replace damaged or stretched circlips.
- The circlip must fit completely inside the groove.
- Replace the roll pin. Installed position: The slit -A- should be in line with the line of force -arrow-.
Bolts and Nuts
- Loosen the bolts and nuts opposite the tightening sequence.
- Bolts and nuts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.
- Especially delicate parts, such as a clutch pressure plate, must not be distorted. Loosen and tighten the bolts and nuts in stages and in a diagonal sequence.
- The tightening specification stated applies to non-lubricated nuts and bolts.
- Always replace self locking nuts and bolts.
- Use a wire brush to clean the threads of bolts that were installed with locking fluid. Next, use liquid locking fluid AMV 185 101 A1 to install the bolts.
- Clean the threaded holes for the self locking bolts or for the bolts coated with locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
- Please make sure that the thread pitch is correct so that the proper thread tap is used during cleaning, and the thread does not get damaged.
Bearings
- Insert all bearings in the transmission housing using transmission oil.
- Heat the tapered roller bearing inner races to approximately 100 °C (212 °F) using the inductive heat unit VAS6414 before installing. Press on until seated when installing, so there is no axial clearance.
- Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
- Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.
- Set the needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward the installation tool.
Adjusting Shims
- Measure the adjusting shims at several locations with a micrometer caliper. Tolerance variations make it possible to find the exact shim thickness required.
- Check for burrs and damage.
- Only install perfect shims.
Synchronizer Rings
- Do not interchange them. When reusing synchronizer rings, always install them to the same gear.
- Check for wear and replace as necessary.
- Check the grooves -arrow 1- on the synchronizer ring -A- and the inner race for flat areas (grooves are worn).
- The coating on the synchronizer rings must not be damaged.
- If an intermediate ring -B- is installed, check the outer friction surface -arrow 2- and the inner friction surface -arrow 3- for grooves and scoring.
- Check taper of the drive gear for grooves and scoring.
- Coat the synchronizer ring with transmission fluid and then install.
Toothed Gears, Synchronizer Hubs
- Heat the synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit VAS6414 before installing. Press on until seated when installing so there is no axial play.
- Heat the toothed gears to approximately 100 °C (212 °F) using the inductive heat unit VAS6414 before installing. Press on until seated when installing so there is no axial play.
- Pay attention to the installed location.
Selector Gears
- After installing, check 1st through 6th gear for minimal amount of axial clearance and for ease of movement.
Clutch Mechanism and Clutch
- When removing the transmission, remove the clutch slave cylinder without opening the lines.
- If the clutch slave cylinder is removed with the hydraulic line attached, do not press the clutch pedal. Otherwise the piston will be pressed out of the clutch slave cylinder.
- Do not tilt the clutch pressure plate. Loosen and tighten the bolts diagonally and in small steps.
- To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing and the flywheel running surface with a clean cloth.