Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

>A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Shop Instructions, are summarized here. They apply to this repair information.

Special Tools and Equipment 

Transmission 

• Make sure that the alignment sleeves between the engine and transmission are positioned correctly when installing the transmission.
• Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.
• After installing the transmission and/or bevel box, check the transmission fluid level in the manual transmission and the gear oil level in the bevel box; (Manual Transmission, refer to TRANSMISSION FLUID, CHECKING )

Capacity, Manual Transmission	Bevel Box Capacity
Refer to the Fluid Capacity Tables	Refer to the Fluid Capacity Tables

Seals, Sealing Rings 

• Thoroughly clean the separation surfaces and apply sealing paste AMV 188 200 03.
• Apply the sealing compound evenly and not too thick.
• Replace gaskets and oil seals.
• After removing the gaskets, examine the contact surface on the housing/shaft for burrs resulting from removal or for other signs of damage.
• Before installing the radial shaft seals, lightly oil the outer circumference and fill the space between sealing lips halfway with sealing grease G 052 128 A1 -arrow-.
  Fig 1: Identifying Oil Seals Sealing Lips

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side of the seals point toward the fluid to be sealed in.
• Check the transmission fluid level, refer to TRANSMISSION FLUID, CHECKING .
• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

Sealant 

• Always thoroughly clean the separating surfaces on the housing before applying the sealant.
• Apply the sealing compound AMV 188 200 03 evenly and not too thick.
• Do not allow any sealing compound to get into the ventilation holes.

Fasteners 

Note the following when working on the fasteners:

• Replace the circlips.
• Do not overstretch the circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. The slot must be longitudinal to the line of force.

Bolts and Nuts 

Note the following when working with bolts and nuts:

• Always loosen or tighten bolts and nuts on covers and housings diagonally.
• Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
• The tightening specifications stated apply to unoiled bolts and nuts.
• Always replace the self-locking nuts and bolts.
• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.
• Use a thread cutter to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.
• Please make sure that the thread pitch is correct so that the proper thread cutter is used during cleaning, and the thread does not get damaged.

Bearings 

• Install the new tapered roller bearings. It is not necessary to oil them.
• Install needle bearings with the lettered side (thicker metal) facing the fitting tool.
• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.
• Heat the tapered roller bearing inner races to approximately 100 °C (212 °F) with the inductive heat unit VAS 6414 before installing. Press on to the stop when installing, so there is no axial clearance.
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Adjusting Shims 

• Measure the adjusting shims at several locations with a micrometer caliper. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Only install perfect shims.

Synchronizer Rings 

• Do not interchange them. When reusing synchronizer rings, always install to the same gear.
• Check for wear and replace if necessary.
• Check the grooves -arrow 1- on the synchronizer ring -A- and the inner race for flat areas (grooves are worn).
  Fig 3: Identifying Wear On Synchronizer Rings

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The coating on the synchronizer rings must not be damaged.
• If an intermediate ring -B- is installed, check the intermediate ring on the outer contact surface -arrow 2- and inner contact surface -arrow 3- for >>grooves<<, >>scoring<< and >>blue coloring (from overheating)<<.
• Check taper of drive gear for >>grooves<< and >>scoring<<.
• Coat the synchronizing with transmission fluid and then install.

Gears 

• Before pressing on, clean and warm to 100 °C (212 °F) max. with inductive heat unit VAS 6414.

Selector Gears 

• After assembling, check the selector gears for minimum axial clearance and ease of movement.

Clutch 

• Do not tilt the clutch pressure plate. Loosen and tighten it diagonally and in small steps.
• Clean the clutch housing and the running surface on the flywheel thoroughly with a cloth to reduce odors on a burned clutch.