Assembling the Transmission

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Press the new grooved ball bearing -item 4- onto the input shaft, refer to INPUT SHAFT OVERVIEW .
The reverse gear selector fork -1- is placed in its installed position on the 5th and 6th gear selector shaft with selector fork -2-.

Fig 1: Identifying Reverse Gear Selector Fork Mounted On Selector Shaft With 5th And 6th Gear Selector Fork
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-- Install the input shaft -1-, the 5th/5th gear output shaft -2- and the 5th/6th gear selector shaft with selector fork -3-, the reverse gear selector fork -4- and reverse gear shaft -5-.

Fig 2: Identifying Input Shaft, 5th/6th Gear Output Shaft, 5th/6th Gear Gearshift Rod, Reverse Gear Shift Fork And Reverse Shaft

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The shift jaw -arrow A- on the reverse gear selector fork faces the outside of the transmission. The shift jaw -arrow B- on the 5th/6th gear selector shaft with selector fork must face toward the inside of the of the transmission.

-- Then, install the differential -1-.

Fig 3: Identifying Differential, Input Shaft & Output Shaft

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NOTE: A 2nd technician is needed to help install the shafts into the clutch housing.

-- Hold the 1st through 4th gear output shaft -3- with the selector shaft with selector fork -4- in the right hand as illustrated.

-- Lift the differential slightly with the left hand.

-- Have the second technician lift the input shaft, the 5th/6th gear output shaft -2- together with the reverse gear shaft slightly at the same time.

-- Install the 1st through 4th gear output shaft in the -direction of the arrow-.

Parts of the input shaft, output shafts and final drive gear/differential must engage.

-- Place the shafts and the differential in their busing seats with help from a second technician.

-- Install the Support Bridge 30-211 A for the input shaft to the clutch housing.

Fig 4: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE: The clutch housing is shown in the illustration rotated 180°.

-- Install the bolt -A- just far enough until the input shaft starts to lift.

Fig 5: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008

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There is a flattened area on the grooved ball bearing and the bearing mount.

The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark this flat side with a colored mark.

-- 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 illustration).

-- 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, inductive heat unit 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.

Apply Sealant AMV 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 6: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

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

Fig 7: Allocation Of Bolts

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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.

-- If the retaining sleeve for the gear shift shaft was removed, then install it now all the way onto the tool. Refer to Figure.

-- Turn the transmission so that the opening for the gear shift shaft faces up in the assembly stand.

NOTE: Use the Pry Lever 80 - 200 to press against the spring force of the securing bushing -direction of arrow- so that the gear shift shaft -1- does not touch the securing bushing -2- when installing.

Fig 9: Securing Bushing

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

Fig 10: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

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NOTE: The cover is not shown in the illustration. Refer to TRANSMISSION HOUSING OVERVIEW .

-- 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 11: 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- for the gear shift cover -4-.

Fig 12: Identifying Back-Up Lamp 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 input shaft seal so that it is flush.

Fig 13: Driving In Input Shaft Oil Seal Flush

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-- Install the clutch slave cylinder with release bearing. Refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING .

-- Move the shift lever through all the gears.

-- Install the sealing cap as follows:

Fig 14: Identifying Input Shaft Sealing Cap Types

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-I- = Metal sealing cap, secured with a circlip -A-.

-II- = Plastic sealing cap, without a circlip.

Fig 15: Identifying Mounting Areas/Profiles For Sealing Caps (Metal Cap) And (Plastic Cap)

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Mounting area for the sealing cap	Sealing Cap	Installation
-Arrow A- surface is vertical.	Metal	Refer to Fig 16
-Arrow B- surface is at an angle.	Plastic	Refer to Fig 18

Fig 16: Identifying Tool Assembly To Install Metal Cap On Transmission Housing

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-- Install the sealing cap all the way into the transmission housing.

-- Secure the cap with the circlip -A-.

Fig 17: Identifying Transmission Housing Without Sealing Cap Circlip

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Fig 18: Identifying Tool Assembly To Install Plastic Cap On Transmission Housing

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-- Install the cap all the way into the transmission housing.

Continuation for All

Always pay attention to the sealing cap allocation, refer to Fig 15.
Leaks will happen if the incorrect sealing cap is installed.
Use the correct sealing cap

-- Install the flange shafts with the springs, thrust washers and tapered rings.

Fig 19: Identifying Flange Shaft

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