Assembly
The assembly procedure is not in sequential steps, but grouped in sub-assemblies.
Drive Flange and Adjusting Ring Installation
- Install left and right adjusting rings and align marks at depth previously measured
- Lubricate threads with MoS2 grease
CAUTION: Do not tighten left side adjusting ring until clutch housing has been installed and bolts torqued.
- Install drive flange using VW 391
- Insert wave washer
- Press circlip into groove with VW 244b and at same time check that washer is centered
Rear Main Shaft Installation
- Screw front and rear main shafts together then back off one spline
- Push reverse gear on and install new circlip
Gear Carrier/Gearshift Housing Assembly
- Tighten to 225 Nm (162 ft lb), then back off and retighten to 225 Nm (162 ft lb)
- lock ring by peening twice with tool (A)
- Tap on pinion with plastic hammer to install
- Turn reverse shaft so that reverse sliding gear slips onto splines properly
- Align flat on bearing with recess in housing
- Press locking key (B) into recess (arrow)
Gear Shift Housing Installation
- Guide inner shift lever into 3rd/4th gear selector shaft (arrow) when installing
- Insert 3rd/4th gear shift fork and check for free movement when pressing in shafts
- Lift pinion shaft and guide carefully when pressing in
- After installing shafts, adjust shift forks
Shift Fork Adjustments
- Position gear carrier, with shim S3, in tool VW 294b without gasket for gear carrier Service and Repair-- Differential Adjustments, 091 Transmission
- Length of bolts VW 294b = 106 mm (4-3/16 in.)
- Tighten retaining ring VW 294b/7 by hand
- Install shift forks for 1st/2nd and 3rd/4th gears
CAUTION:
^ Shift fork for 1st/2nd gear (wider fork, marking: No. 551 A) is installed with flat side away from gear carrier.
^ Shift fork for 3rd/4th gear (thinner fork, marking: No. 561 A) is installed with flat side toward gear carrier.
- Install relay lever Support together with relay lever
- Put 1st/2nd gear selector shaft in 2nd gear position
- Slide operating sleeve with fork over synchronizing teeth until it is against 2nd gear
- Center shift fork in groove of operating sleeve and tighten clamp screw
CAUTION: Shift fork must not rub or exert pressure on sides of groove in operating sleeve when in neutral position or when gear is engaged. THERE MUST ALWAYS BE CLEARANCE.
- Select 1st and 2nd gears several times while turning main shaft and check clearance of shift fork in operating sleeve in each position
- If necessary, alter shift fork position until there is the same amount of clearance on selector shaft in both end positions
- Tighten clamp screw to 25 Nm (18 ft lb)
- Put 3rd/4th gear selector shaft in 3rd gear position
- Adjust 3rd/4th gear shift fork in same way as 1st/2nd gear shift fork
CAUTION: For correct adjustment of 3rd/4th gears, main shaft ball bearing must be pressed fully into gear carrier housing.
- Press reverse gear selector shaft into reverse gear position
NOTE: After repair work on gear carrier housing, adjust axial play in reverse sliding gear before adjusting reverse gear.
- Adjust reverse gear so that sliding gear is fully in mesh with teeth on operating sleeve for 1st/2nd gear (arrow)
- Tighten union nut on relay lever support
- Shift out of reverse gear and press sliding gear lightly toward gear carrier housing. Clearance between reverse gear and 2nd gear on main shaft must be:
a = min. 0.5 mm (0.020 in.)
- Engage 2nd gear
- Check clearance between operating sleeve and reverse sliding gear in this position and adjust if necessary
- Check interlock mechanism
- When gear is engaged it must not be possible to engage any other gear
Servicing Clutch Housing Assembly
- Pry out main shaft seal using VW 681
- Install main shaft seal, drive in using VW 244b
- Remove release shaft bushing, refer to image
- Drive in flush
- Starter bushing can be removed and installed using VW 222a when transmission is removed
Drive Shaft Oil Seal and Reverse Gear Circlip Installation
- Press seal in flush
- Press Circlip into groove
- Squeeze into groove with waterpump pliers
Gear Carrier Housing Adjustments
- Check that when gear is engaged it is not possible to engage any other gear
NOTE: When reverse relay shaft and brackets have been removed, play between reverse gear and pin (arrow) on relay shaft must be adjusted by moving shaft and brackets vertically (as shown).
- Install gear carrier with reverse gear in setting tool VW 294b
- Loosen bolts on both brackets
- Slide bracket A down against shaft (C) until pin (arrow) on relay shaft is firmly against reverse gear
- Pull bracket back slightly until there is clearance between pin and reverse gear
- Tighten bolts on bracket (A)
- Press bracket B against relay shaft until relay shaft is installed firmly and without play
- Tighten bolts on bracket (B)
Gear Shift Housing Assembly
- Install selector shaft bushing using VW 418a
- Install selector shaft oil seal using VW 423
- Fill space between lips with multipurpose grease
- Image shows position of selector shaft and rocker shaft parts when installed
Main Shaft Assembly
- Install 3rd/4th gear circlip
- Slide sleeve over shaft until it contacts splines for hub (arrow). It may be necessary to back out knurled screw
- Place new circlip (arrow) on sleeve and push over splines with tube until circlip snaps into groove
- Press synchronizer rings onto gear by hand and measure gap a with feeler gauge
^ a = New: 1.0-1.7 mm (0.039-0.067 in)
Wear limit: 0.5 mm (0.020 in)
- Assemble 3rd/4th gear synchronizer
^ Identification grooves (arrows) of sleeve and hub are on opposite sides. Groove on sleeve (white arrow) faces 4th gear
^ Sleeve and hub are not matched and can be replaced separately
- Assemble parts at several positions before installing to determine position of smoothest operation with minimum backlash
- Slide sleeve over synchronizer hub. Matched position is not necessary
- Insert keys and install springs with ends offset 120°. Angled ends of springs must fit into keys
- Turn synchronizer ring until grooves are in line with keys
- Identification groove on sleeve faces 4th gear (arrow)
- Slide sleeve over shaft and turn knurled screw in until groove (arrow) is exposed. If necessary, use M6 x 60 bolt instead of knurled screw
- Push circlip on until it snaps into groove
- Install main shaft ball bearing
- Press in so that recess in bearing is aligned with recess (arrow) in housing
- Install locking key to prevent bearing from turning
- Press pinion needle bearing in flush using VW 295
CAUTION: When installing, lettered side of bearing (thicker material) must face installing tool
Pinion Shaft Assembly
- Depress spacer spring by pushing down on 4th gear in a press using VW 460/3
- Fit 4th gear circlip securely in groove
- Heat inner races of tapered roller bearing to about 100°C (212°F) and press on
- efore tightening needle bearing inner race, let tapered roller bearing cool to room temperature
- Heat 1st gear needle bearing's inner race to about 60°C (140°F) and screw on as far as possible by hand
- Place pinion shaft in tool 2052 and tighten wing nut lightly
- Tighten inner race to 210 Nm (152 ft lb)
- Lubricate bearings with transmission oil and tighten retaining ring to 225 Nm (162 ft lb)
- Lock retaining ring by peening two places with tool (A)
- Check turning torque of tapered roller bearing,
- Turn pinion shaft in both directions about 15-20 times
- Turn further and read turning torque
^ new bearings: up to 210 Ncm (180 in. lb)
^ used bearings*: up to 70 Ncm (61 in. lb) (*after running at least 30 miles)
- If no turning torque can be measured, check for rock at end of pinion. There must not be any detectable movement
- If YES, replace tapered roller bearing
- Press synchronizer rings onto gear by hand and measure gap (a) with feeler gauge
^ Gap a = New 1.0-1.7 mm (0.039-0.067 in)
Wear limit 0.5 mm (0.020 in)
- Assemble 1st/2nd gear synchronizer
NOTE:
- Gear teeth on sleeve and long collar on hub must face 1st gear when installing
- Sleeve and hub are not matched and can be replaced separately
- Slide sleeve over synchronizer hub. Matched position is not necessary
- Insert keys and install springs with ends offset 12O°. Angled ends of springs must fit into keys
- Position synchronizer assembly on needle bearing inner race so that old marks on long collar of synchronizer hub (from lugs on needle bearing inner race) are now opposite gaps on needle bearing inner race
- Sleeve and hub are not matched and can be replaced separately
- Turn synchronizer ring until grooves are in line with keys
- Measure end play with feeler gauge
- Adjust by selecting suitable circlip, play should be 0.05-0.20 mm (try to keep lower limit)
- Press pinion needle bearing in gear carrier housing until seated