Disassembly And Assembly: Transmission: Assembly
-- Install the differential.
-- Always replace the seals -arrows- for the output shaft bearing support
The illustration only shows three of the four seals.
-- Insert input shaft -1- and the output shaft -2- together.
-- Tighten the output shaft bearing support nuts to specification, see -item 11- in INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SELECTOR FORKS OVERVIEW .
-- Mount the reverse gear -3- on the needle bearing inside the clutch housing.
The shoulder -arrow- faces away from clutch housing.
-- Make sure the reverse gear shaft -4- is complete, refer to REVERSE SHAFT . Do not mount the support on the reverse gear shaft.
-- Install the reverse gear shaft into the clutch housing.
-- Clean all threaded holes in the reverse gear shaft support of locking compound; the cleaning can be done using a thread tap.
-- Mount the reverse gear shaft support.
-- Install the reverse gear selector fork -1- with the support for the reverse gear selector fork -2- , the spring -3- and the sliding piece -4- .
Reverse Gear Location
-- Install the reverse gear selector fork -A- .
-- Install the selector forks -B- together with the rails.
The reverse gear shaft supports -C- are located in front of the rails.
-- Install the (M8 x 100) stud bolts -A- into the reverse gear shaft support so that the shaft is aligned after fitting the transmission housing.
-- Align the rails.
The shift segments must be installed in the grooves on the locking collars.
-- Apply sealing pasteAMV 188 200 03 evenly over the sealing surface on the clutch housing.
-- Install the transmission housing and tighten the bolts to specification, refer to -item 15- in TRANSMISSION HOUSING AND SHIFT MECHANISM OVERVIEW .
Install the bolts for the reverse gear shaft support -arrow- as follows:
-- Install the bolt -a- .
-- Remove the (M8 x 100) stud bolts -A- (see upper illustration).
-- Install the bolt -c- .
Tightening Sequence
-- Tighten the bolt -a- .
-- Tighten the bolt -b- .
-- Tighten the bolt -c- (see upper illustration).
-- Install the support pin -arrow- for the selector forks. To do this, align the shift mechanism using a screwdriver, so that the relevant support pin can be installed.
-- Apply the sealing pasteAMV 188 200 03 evenly on the sealing surface on the sealing cover.
-- Install the gear shift unit.
Install the gearshift shaft as follows:
-- Move the gear shift rail into the neutral position.
-- Apply the sealing pasteAMV 188 200 03 evenly on the sealing surface on the cover.
-- Move the gear shift shaft into neutral.
-- Position the selector shaft so that the selector finger -arrow- is inserted into the selector rails.
-- Tighten the selector shaft cover bolts to specification, refer to -item 17- in TRANSMISSION HOUSING AND SHIFT MECHANISM OVERVIEW .
-- Install both flange shafts with springs, thrust washers and tapered rings. For the tightening specifications, refer to one of the following:
- Make sure the Bracket - Multiple Use 30-211A and the Support Bridge T10323 are installed.
-- Secure the bolt on the Bracket - Multiple Use 30-211A with the nut -A- .
The groove all the way around -arrow- faces the transmission housing.
-- Warm the 5th gear to approximately 100 °C using Hot Air Blower VAG1416.
Wear safety gloves.
-- Install the 5th gear.
-- Before reinstalling drive gear and synchronizer ring for 5th gear, press the synchronizer ring onto the taper of the drive gear and measure the gap dimension -a- using a feeler gauge.
| Gap Dimension -a- | Installation Dimension | Wear limit |
|---|---|---|
| 5th Gear | 1.1 to 1.7 mm | 0.5 mm |
-- Install 5th gear selector gear with needle bearing.
-- Place the 5th gear synchronizer ring onto the selector gear.
-- If disassembled, assemble the 5th gear locking collar/synchronizer hub Figure.
The pointed teeth on the locking collar -arrow 1- and the high collar on the synchronizer hub -arrow 2- face the transmission housing.
The notches -arrow 3- on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring, refer to Fig 18 (below).
-- Cover all openings with a cloth to prevent foreign objects from getting into the transmission.
-- Warm the 5th gear synchronizer hub to approximately 100 °C (212 °F) using Hot Air Blower VAG1416.
Wear safety gloves.
-- Install the 5th gear synchronizer hub
Make sure there is enough clearance when installing the synchronizer ring.
-- Loosen the support for the input shaft.
-- If it has not been done already, clean any locking compound residue from the threaded hole for the synchronizer hub bolt and 5th gear wheel with a thread tap.
Otherwise, there is the danger that the screws could shear off.
-- Screw-in new synchronizer hub bolts and 5th gear.
The outer diameter -arrows- faces the 5th gear.
-- Tighten the synchronizer hub and 5th gear drive gear bolts -A- and insert 5th gear -arrow 1- and 1st gear -arrow 2- and load it in the -direction of arrow 3- .
-- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear wheel cannot turn. Both bolts can be loosened now.
-- Install the 5th gear shift fork.
-- Engage 5th gear. Loosen the bolt -1- . Push the locking collar and the shift jaw in the -direction of the arrows- . Tighten the bolt -1- .
- Check measurement: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.
-- Install 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.
-- Move the shift lever (selector lever) through all the gears.
-- Install the transmission housing cover, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR OVERVIEW .
-- Install the release bearing guide sleeve, refer to CLUTCH RELEASE MECHANISM OVERVIEW .
-- Install the clutch release lever and release bearing, refer to CLUTCH RELEASE MECHANISM OVERVIEW .
-- Fill the transmission fluid, refer to Transmission Fluid, Checking and Filling .