Disassembly and Assembly
Transmission, Assembly Sequence
Special tools, testers and auxiliary items required
• Drip Tray (V.A.G 1306)
• Hexagon Spanner Head (T40208)
• Assembly Plate (T40211/1)
• Adapter (T40211/2 and T40211/3)
• Workshop Crane (VAS 6100)
• Engine/Transmission Holder (VAS 6095) or Holding Fixture (VW 313)
• Kukko (20-10)
• Puller (Kukko 18-0) or Kukko 18-1
• Alignment Fixture (T10356/5)
• Thread Locking Compound (D 197 300 A2)
• Sealing Paste (AMV 188 001 02)
- Attach transmission to assembly stand. Refer to => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.
- Place Drip Tray (V.A.G 1306) under transmission.
- Open the oil drain plug - 1 - and drain the transmission fluid.
- Install and tighten the oil drain plug - 1 -. Tightening specification => [ (Item 9) Oil drain plug ] Bearing Housing Assembly Overview.
CAUTION!
There is a risk of destroying the differential.
• When removing the final drive cover, make sure the differential does not fall out.
• Do not install a differential that has fallen onto the floor.
- Remove the bolts - arrows - and the final drive cover with the flange shaft.
- Remove the differential.
Transmission with R tronic
- Remove the shift actuator for the R tronic. Refer to => [ Shift Actuator, R Tronic ] Shift Actuator, R Tronic.
- Remove both the hydraulic unit and the reservoir. Refer to => [ Hydraulic Unit ] Hydraulic Unit - Removing.
Manual transmission
- Remove bolts - 1 through 3 -.
- Remove both the shift unit - 4 - and the shift/selector relay lever.
Continuation for all transmission
- Engage two gears. Push the selector rods - 2 and 3 - to the right with a screwdriver.
- Remove the bolts - arrow - and remove the end cover.
- Open the peening on both nuts - arrows -.
- Remove the spring pins - 1 - with a drift.
- Remove the nuts - 1 - and - 2 - with the Hexagon Spanner Head (T40208).
- Remove both the reverse drive gear - 3 - and thrust washers.
- Remove washer - 1 -.
- Remove the locking collar with synchronizer hub - 2 - and shift fork - 3 -.
- Remove the synchronizer ring - 4 -, reverse gear gear wheel - 5 - and needle bearing - 6 -.
- Remove the reverse gear wheel - 7 -, use an assembly lever if necessary.
- Remove the nut - A -.
- Remove bolts - arrows - and remove the transmission housing - B -.
- Mount the Assembly Plate (T40211/1) and Adapter (T40211/2 und T40211/3).
- Install the nuts for reverse gear - A - and - B -, which were removed earlier, and tighten them hand tight.
- Engage two gears. While doing this, push the shift fork - 1 - and - 2 - in direction of - arrow -.
- Remove the drive pinion grooved nuts - 3 - and - 4 -.
- Carefully remove the drive pinion - 1 - using a rubber hammer. While doing this, support the drive pinion from underneath.
- Remove the taper roller bearing inner race - 2 -.
- Remove bolts - 1 through 4 -.
- Engage the Workshop Crane (VAS 6100) to the Assembly Plate (T40211/1).
- Lower the gear and secure it to the Engine/Transmission Holder (VAS 6095) or Holding Fixture (VW 313).
- Engage two gears. While doing this, push the shift fork - 3 - and - 4 - in direction of - arrow -.
- Remove both grooved nuts.
- Remove the roller sleeve inner race - 1 - together with the helical gear drive gear - 2 -.
- A - Two-Arm Puller (Kukko 20-10).
- Remove the helical gear drive gear - 3 -.
- Mount two pullers - A - on the bearing cover as illustrated.
- A -, for example, Puller (Kukko 18-0) or Kukko 18-1
- Remove the bearing cover evenly. While doing this, rotate the spindles - B - and - C - maximum 180°.
Transmission, assembling
Install in reverse order, paying attention to the following:
• Check the 3rd to 6th gear shift forks - 4 and 5 - for wear. Refer to => [ Checking 3rd to 6th Gear Shift Forks for Wear ] Shift Forks and Shift Rails Assembly Overview
• Check the 3rd to 6th gear locking collars for wear. Refer to => [ Locking Collar for 3rd to 6th Gears, Checking
for Wear ] Description and Operation
• Housing joint surfaces must be cleaned.
- Install both input shafts - 1 - and - 2 - together with the shift forks - 3 through 5 - into the Assembly Plate (T40211/1).
- Secure the both input shafts with the reverse gear nuts - A - and - B - hand tight.
- Secure the shift rails - 1 - with a 5 mm drift - A -.
- Mount the bearing housing - 2 -. While doing this guide both shift rails into the bearing housing.
- Mount the helical gears - 3 and 4 - and the Assembly Fixture (T10356/5).
• Always replace the nut - 5 -.
• Secure the grooved nut - 6 - with Locking Compound (D 197 300 A2).
• Grooved nut installation position - 6 -: the collar - arrow - faces the ball bearing.
• Engage two gears to tighten the nuts.
- Install the nut - 5 - and grooved nut - 6 - hand tight.
- Tighten the nuts - 5 and 6 - evenly 2 turns (alternating 180° additional turn).
- Remove the nut - 5 - and remove the Assembly Fixture (T10356/5).
- Mount the roller bearing inner race - 2 -, washer - 3 - and new nut - 4 -.
- Tighten the grooved nut - 1 - and the nut - 4 - evenly (alternating 180° additional turn)
- Tighten and caulk the nut - 4 -. Tightening specification => [ (Item 14) Nut ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Tighten the grooved nut - 1 -. Tightening specification => [ (Item 20) Grooved nut ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
• Secure the grooved nut - 5 - with Locking Compound (D 197 300 A2).
• Grooved nut installation position - 5 -: the collar - arrow - faces the ball bearing.
- Install the grooved nut - 5 - and tighten. Tightening specification => [ (Item 21) Grooved nut ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Install 2 alignment sleeves - 1 - and 2 new O-rings - 2 - in the transmission housing.
- Install the helical gear output gear - 3 -.
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
- Engage the Workshop Crane (VAS 6100) on the Assembly Plate (T40211/1) and lift the gear set.
• A second technician is needed for the next two steps.
- Align the gear set in the installation position above the transmission housing.
- Slowly lower the Workshop Crane (VAS 6100). While doing this, the second technician needs to guide the gear set into the transmission housing.
- Remove the Workshop Crane (VAS 6100) and Assembly Plate (T40211/1).
- Install the bolts - 1 -. Tightening specification => [ (Item 8) Hex socket bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Install the bolt - 2 -. Tightening specification => [ (Item 22) Bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Install the bolt - 3 -. Tightening specification => [ (Item 23) Hex socket bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Install the bolt - 4 -. Tightening specification => [ (Item 6) Bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Install the new rings - arrows -.
- Warm the tapered roller bearing inner race - 2 - to maximum 100 °C.
- Install the drive pinion - 1 - and the taper bearing bearing inner race - 2 -. Wear protective gloves.
- Engage two gears. While doing this, push the shift fork - 1 - and - 2 - in direction of - arrow -.
• Secure the grooved nuts - 3 and 4 - with Locking Compound (D 197 300 A2).
• Grooved nuts installation position - 3 and 4 -: the collar faces the tapered roller bearing.
- Install and tighten the drive pinion grooved nut - 4 -. Tightening specification.
- Install and tighten the drive pinion grooved nut - 3 -. Tightening specification.
Tightening specification
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
- Position the transmission housing - B - and tighten the bolts - arrows -. Tightening specification => [ (Item 1) Bolt ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Tighten the nuts - A -. Tightening specification => [ (Item 19) Nut ] Input Shaft, Output Shaft, Bearing Housing and Shift Forks Assembly Overview.
- Mount the needle bearing - 6 -, reverse gear gear wheel - 5 - and needle bearing - 4 -.
- Remove the locking collar with synchronizer hub - 2 - and shift fork - 3 -.
- Mount the washer - 1 -.
- Install the reverse gear wheel - 7 -.
- Place the thrust washer with the anti-twist mechanism - arrow A - into the recess in the transmission.
- Install the reverse gear guide wheel so that the oil pump drive pin - arrow C - fits into the groove on the guide wheel - arrow B -.
- Engage two gears. Push the selector rods - 2 and 3 - to the right with a screwdriver.
- Remove both the reverse drive gear - 3 - and thrust washers.
- Tighten the new nut - 1 - with the Hexagon Spanner Head (T40208). Tightening specification => [ (Item 27) Nut ] Reverse Gear Assembly Overview.
- Tighten the new nut - 2 - with the Hexagon Spanner Head (T40208). Tightening specification => [ (Item 15) Nut ] Reverse Gear Assembly Overview.
- Caulk the nuts - arrows -.
- Install the spring pins - 1 - with a drift.
- Install the thrust washer - 1 - so that the anti-twist mechanism is in the center between the holes - 2 - and - 3 -.
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
- Mount the end cover and tighten the bolts - arrows -. Tightening specification => [ (Item 1) Bolt ] Reverse Gear Assembly Overview.
- Install the differential.
- Replace the O-rings => [ (Item 9) O-ring ] Shaft Seal and Right Flange Shaft Assembly Overview and => [ (Item 10) O-ring ] Shaft Seal and Right Flange Shaft Assembly Overview on the final drive cover.
- Insert the final drive cover with the flange shaft and tighten the bolts - arrows -. Tightening specification => [ (Item 2) Bolt ] Shaft Seal and Right Flange Shaft Assembly Overview.
- Bring the selector rods in the transmission into the position shown.
• The openings in the selector rod yokes - 1 through 4 - must align.
• Alignment sleeves (quantity: 2) installed.
Manual transmission
- Apply Sealing Paste (AMV 188 001 02) on the housing separating surface.
• Bolts - 1 through 3 - tightening specifications, refer to => [ Shift Unit on Manual Transmission Assembly Overview ] Shift Unit on Manual Transmission Assembly Overview.
• The transmission shift lever is in the neutral position - 4 -.
- Install the shift unit - 4 -.
- Mount the shift/selector relay lever with the bolts - 1 and 2 -.
Transmission with R tronic
- Install the shift actuator for the R tronic. Refer to => [ Install the shift actuator. ] Shift Actuator, R Tronic.
- Install the hydraulic unit and reservoir. Refer to => [ Hydraulic Unit, R Tronic Assembly Overview ] Hydraulic Unit, R Tronic Assembly Overview.
Continuation for all transmission
- Fill gear oil. Refer to => [ Transmission Capacities ] [1][2]Capacity Specifications.