Transmission, Without A Sealing Cap CIRCLIP: Assembly

Press the new grooved ball bearing INPUT SHAFT OVERVIEW onto the input shaft.

-- First, insert the input shaft -1-, output shaft for 5th/6th gears -2- together with the selector shaft with selector forks -3-, selector fork -4- and reverse shaft -5-.

Fig 1: Inserting Input Shaft, Output Shaft For 5Th/6Th Gears Together With Selector Rod, Shift Fork And Reverse Shaft

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-- Then install the differential -1-.

Fig 2: Inserting 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 output shaft for 1st through 4th gear -3- and the selector shafts with selector forks -4- with the right hand.

-- Slightly lift the differential with the left hand.

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

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

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

-- Together with a second technician, now place the shafts and differential in their bearing seats.

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

Fig 3: 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.

With some transmissions, there are flattened sides -A- on the input shaft grooved ball bearing and on the bearing mount -B-.

Check the input shaft grooved ball bearing and the transmission housing.

Fig 4: Flattened Areas on the Grooved Ball Bearing and Bearing Seat in the Transmission Housing, Approximately from Transmission Build Date 21 February 2008

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Input Shaft Grooved Ball Bearing and Transmission Housing
No flattened sides on the grooved ball bearing -A- and bearing mount -B-.
Flattened sides on the grooved ball bearing -A- and bearing mount -B- , refer to Fig 8.

From transmission build date 4 October 2006 through approximately 21 January 2008

One washer each is inserted above and below the input shaft grooved ball bearing INPUT SHAFT OVERVIEW .

Upper washer	Outer circumference	78.6 mm
Lower washer	Outer circumference	85 mm

Measure the shoulder above the grooved ball bearing mount.

Fig 5: Measuring Shoulder Above Grooved Ball Bearing Mount

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Shoulder above grooved ball bearing	Dimension "a"	Upper washer
Through transmission build date 9 April 2006	10 mm	no
From transmission build date 10 April 2006	10.7 mm	yes

The area under the grooved ball bearing seat in the transmission housing has been changed -arrow-

Fig 6: Identifying Bearing Seat

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Area below the bearing seat		Lower washer
Through transmission build date 9 April 2006	Not deeper.	no
From transmission build date 10 April 2006	Slightly deeper.	yes

-- Place a washer (85 mm outer circumference) -1- on the grooved ball bearing -2-.

Fig 7: Placing Washer On Grooved Ball Bearing

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On some transmissions:

Fig 8: Flattened Areas on the Grooved Ball Bearing and Bearing Seat in the Transmission Housing, Approximately from Transmission Build Date 21 February 2008

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Flattened areas -A- on the input shaft grooved ball bearing and bearing mount -B-.

Do not place any washers above and below the grooved ball bearing.
The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark the flattened side with color.

-- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (next illustration).

-- Heat the transmission housing in the area near 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, 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.

Align the mark on the grooved ball bearing -A- with the mark on the transmission housing -B- and mount the transmission housing.

Fig 9: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

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-- Heat the transmission housing with the hot air gun V.A.G 1416 in the grooved ball bearing/input shaft bearing set area to 100°C (212°F) for approximately 10 minutes.

-- Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

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

Fig 10: Allocation Of Bolts As Replacement Parts

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A - Bolt with a permanent washer

B - Bolt without a washer

C - Bolt with a permanent washer

-- If a washer was mounted on the grooved ball bearing before installation, then a washer -1- (outer diameter = 78.6 mm) must be installed after installation -2-..

Fig 11: Identifying Laying Washer Above Grooved Ball Bearing

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-- Install the grooved ball bearing/input shaft locking ring -1-.

Fig 12: Identifying Circlip & Special Tool VW 309

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-- Remove the bracket 30-211 A for the input shaft.

-- Install the selector shaft locking sleeve all the way onto the tool, refer to Figure.

-- Turn the transmission with the opening for the selector shaft in the assembly stand upward.

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

Fig 13: Inserting Selector Shaft Into Lower Bearing And Into Shift Forks

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NOTE:

The cover is not shown in the illustration.

-- 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 14: Pressing Selector Shaft Against Lock Sleeve And Guide Downward With Shift Finger

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The gear shift unit 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 unit 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 unit cover -4-.

Fig 15: Identifying Back-Up Lights 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 16: Driving In Input Shaft Oil Seal Flush

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

-- Move the transmission shift lever through all the gears.

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

Fig 17: Driving Cap Into Transmission Housing To Stop Of Thrust Piece T10042

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-- Install the flange shaft, the pressure springs, the thrust washers and the tapered rings.

Fig 18: Installing Flange Shaft

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