General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in this repair information, are summarized here. They apply to this repair information.

Special Tools and Equipment

For a list of special tools used in each repair group, refer to "Special Tools" at the end of the repair group.

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 and other components, refer to the Parts Catalog.
• Fill the transmission fluid when repairing the manual transmission.
• Check the transmission fluid level. Refer to TRANSMISSION FLUID, CHECKING .
• For the correct fluid capacity and fluid specification, refer to Maintenance, Diagnosis .

Sealant

• Always thoroughly clean the separating surfaces on the housing before applying the Sealant.
• Apply the Sealing CompoundAMV 188 200 03 evenly and not too thick.
• Do not allow any Sealing CompoundAMV 188 200 03 to get into the ventilation holes.

O-Rings, Gaskets and Seals

• Replace the O-rings, seals and gaskets.
• After removing the gaskets and seals, always inspect the contact surfaces on the housing or shaft for burrs resulting from removal, and 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 GreaseG 052 128 A1.
  Fig 1: Identifying Oil Seal

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side of the seal points toward the fluid to be sealed in.
• When installing the new shaft seals, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• Lightly lubricate the O-rings before installing them in order to prevent them from being crushed when inserting.
• After replacing the seals, gaskets and O-rings, check the transmission fluid level and fill as necessary. Refer to TRANSMISSION FLUID, CHECKING .

Fasteners

Fig 2: Identifying Circlip & Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Do not overstretch the circlips.
• Installed position for some of the circlips: The circlip is narrower at top. This makes it easier for the pliers to grab the circlip when removing and installing it.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the roll pins. Installed position: The slit -A- should align with the line of force -arrow-.
  Fig 3: Identifying Locking Elements

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolts and Nuts

Fig 4: Identifying Nut And Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• 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 clutch pressure plates, must not be distorted. Loosen and tighten the bolts and nuts in stages and in a diagonal sequence.
• The tightening specification stated apply 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 using liquid locking fluid. Next, use Locking CompoundAMV 185 101 A1 to install the bolts.
• Clean the threaded holes for the self-locking bolts or for the bolts coated with the locking compound. 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 threads are not damaged.

Bearings

• Insert all bearings using transmission fluid.
• Heat the tapered roller bearing inner races to approximately 100 °C (212 °F) using the inductive heat unitVAS 6414 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 drift.

Adjusting Shims

Fig 5: Identifying Micrometer Caliper To Measure Adjusting Shims

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• 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.
• Coat the synchronizer ring with transmission fluid and then install.

Synchronizer Rings for 1st Gear Through 3rd Gear

Fig 6: Identifying Synchronizer Rings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Check the friction surface -arrow 1- of the synchronizer ring -A- and the friction surface -arrow 3- of the inner race -C- for grooves and scoring.
• Check the friction surface -arrows 2- for the outer race -B- for damages (flat areas, disintegrating friction lining).
• Coat the synchronizer rings with transmission fluid and then install.

Toothed Gears, Synchronizer Hubs

• Heat the synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unitVAS 6414 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 unitVAS 6414 before installing. Press on until seated when installing so there is no axial play.
• Pay attention to the installed position.

Selector Gears

• After assembling, check the selector gears for minimum axial clearance and ease of movement.

Clutch

• Do not tilt the clutch pressure plate. Loosen and tighten it 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.