Transmission, Assembly

Press the new grooved ball bearing -item 16- in INPUT SHAFT OVERVIEW onto the input shaft.

-- Install the support bridge T10323 as illustrated.

Fig 1: Mounting T10323

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-- Install the input shaft together and the 5th and 6th gear selector shaft with selector rod into the clutch housing.

Fig 2: Installing Input Shaft Together And Selector Rod For 5Th And 6Th Gears Into Clutch Housing

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Turn the spindle on the support bridge T10323 and lift the input shaft -1- to dimension -a-.

-a- = 15 mm

-- Install the left stub shaft to the differential -A- ; this way the differential can be raised in the following work steps.

Fig 3: Attaching Left Stub Shaft To Differential

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-- Install the differential.

A second technician is needed to perform the following work.

-- Lift the differential in the -direction of the arrow- (2nd technician).

-- First place the 1st and 2nd gear input shaft -1- with the selector shaft with selector rod -2- in the bearing seat and then move it toward the input shaft -3-.

-- Lift the 1st and 2nd gear output shaft on the gear -arrow A- and swing it toward the input shaft (2nd technician).

Fig 4: Lifting 1St And 2Nd Gear Output Shaft On Gear Wheel And Swing It Toward Input Shaft

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-- Guide the reverse gear output shaft -1- under the splines on the gear -arrow A- and place it in the bearing seat -arrow B-.

Turn the spindle on the support bridge T10323 and lower the input shaft approximately 10 mm.

Fig 5: Installation Position, 3rd and 4th Gear Selector Rod

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The shorter brace -arrow- points to the clutch housing.

-- Install the 3rd and 4th gear output shaft -2- together with the 3rd and 4th gear selector shift with selector rod -1-.

-- Install the left stub shaft -3- to the differential.

-- Lower the input shaft just enough -A- by turning the spindle on the support bridge T10323 so that is remains slightly tensioned (lifted approximately 1 m).

Fig 6: Lower Input Shaft

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-- Place the reverse gear selector fork -A- into the reverse gear output shaft slide locking collar.

Fig 7: Placing Reverse Gear Selector Fork -A- Into Reverse Gear Output Shaft Slide Locking Collar

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The stud bolts -arrows- must be vertical before installing the transmission housing.
The grooved ball bearing/input shaft only fits in one position in the transmission housing.

Fig 8: Grooved Ball Bearing/Input Shaft Only Fits In One Position In Transmission Housing
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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.

-- Place a mark on the upper area of the grooved ball bearing and on 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.

-- Apply sealing paste 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 9: Aligning Marking On Grooved Ball And Mount Transmission Housing

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-- Pay attention to the studs for the reverse gear selector shaft with selector fork. Refer to TRANSMISSION, ASSEMBLY .

Do not distort the transmission housing when installing it; hold it parallel to the clutch housing.

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

Fig 10: Installing Grooved Ball Bearing/Input Shaft Locking Ring

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-- Remove the support bridge T10323 from the input shaft -A-.

Fig 11: Removing Support Bridge T10323 From Input Shaft -A-

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-- Install the transmission housing to the clutch housing and tighten the bolts to specification.

Fig 12: Bolting Together Transmission Housing And Clutch Housing

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There are different bolts and tightening specifications, see -item 14- in TRANSMISSION HOUSING AND SHIFT UNIT .

NOTE:

If the bolts -B- have been removed, install them now.

-- Install the stub shaft -A- with the spring, thrust washer and tapered ring.

-- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold tool T10371.

-- Install the stub shaft with the spring, thrust washer and tapered ring.

-- Tighten the stub shaft bolt; when doing this, counter-hold the stub shaft using the counter hold tool T10371.

Install the Shift Unit as Follows:

-- Turn the transmission with the opening for the shift unit in the assembly stand upward.

-- Move the selector shafts with selector rods into the neutral position.

-- Guide the shift unit with the shift finger -1- through the selector shafts with selector rods -A and B- (selector shafts with selector rods, next illustration).

Fig 13: Installing Shift Unit

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Selector shafts with selector rods -A and B-.

Fig 14: Identifying Switching Rockers

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-- Rotate the shift unit in the -direction of the arrow- far enough (→ previous illustration), until it can be guided into the transmission housing.

-- Then, rotate the shift unit in the -direction of the arrow- until the shift finger -2- points in the illustrated position.

Fig 15: Rotating Shift Unit Until Shift Finger Points In Illustrated Position

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-- Install the shift unit with the shift finger into the selector shafts with selector rods -A and B- (→ previous illustration) and at the same time all the way into the transmission housing.