Assembling transmission

If the input shaft or the transmission housing have been replaced, you must first re-determine the thickness of the input shaft circlips → Circlips for input shaft ball bearing, determining .

• Insert hollow shaft in bearing housing and selector fork for 1st and 2nd gear.
• Place reverse gear selector gear with needle bearing, spring and synchro-ring onto hollow shaft.

• The tabs on synchro-ring should engage into recesses in selector gear.

Fig 1: Pressing On Reverse Gear Synchronizing Hub

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• Press on reverse gear synchronizing hub.

• Installation position: high inside collar faces 3rd gear wheel.

• Check axial clearance of reverse selector gear.

Fig 2: Inserting Input Shaft With Needle Roller Bearing Into Bearing Housing At An Angle Toward Rear

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• Insert input shaft - A  - with needle roller bearing - B  - into bearing housing in direction of - arrow  - at an angle toward rear.
• Install reverse gear wheel and tighten 3 bolts for reverse shaft support to 30 Nm.

Fig 3: Installation Position Of Locking Collar In Relation To Synchronizing Hub, Clip, Selector Rod, Selector Fork And Locking Collar

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• Slide reverse gear selector fork - C  - together with locking collar - D  - onto selector rod - B  - and reverse gear synchronizing hub.

• The markings on locking collar and synchronizing hub - arrow  - must coincide.
• The chamfer on locking collar faces reverse selector gear.

• If the holes of selector fork and selector rod coincide, clip in pin with clip - A  -.

Fig 4: Work Surface Of Workshop Press V.A.G 1290 A Aligned So That The 3rd Hole Is Visible Above Work Surface

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• Align work surface of workshop press V.A.G 1290 A so that the 3rd hole - arrow  - is visible above work surface.
• Place holding plate T40088/1 with sleeve T40088/2 onto work surface.
• Insert bearing housing with shafts and selector rods into holding plate T40088/1.

The distance between input shaft - 1  - and thrust disc VW 412 should be approx. 210 mm, so that it is possible to perform the following work steps without changing the position of the work surface.

Fig 5: Pressing On 3rd Gear Wheel

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• Press on 3rd gear wheel.

• Installation position: machined side faces reverse gear synchronizing hub.

• Insert circlip for 3rd gear wheel.

• When replacing gear wheel or hollow shaft:

Re-determine thickness of circlip for 3rd gear wheel:

• Determine thickest circlip that will just fit and install it.

The following circlips are available:

Fig 6: Pressing On Thrust Washer For 3rd Speed Selector Gear Until Limit Stop

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• Press on thrust washer - A  - for 3rd speed selector gear until limit stop.

Fig 7: Installing Needle Bearing For 3rd Speed Selector Gear And Circlip For 3rd Gear Needle Bearing Onto Input Shaft

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• Install needle bearing for 3rd speed selector gear - 1  - and circlip - 2  - for 3rd gear needle bearing onto input shaft.
• Install 3rd speed selector gear with spring and synchro-ring.

• The tabs on synchro-ring should engage into recesses in selector gear.

Fig 8: Pressing On Heated Synchronizing Hub For 3rd And 4th Gear

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• Press on heated synchronizing hub for 3rd and 4th gear

• Installation position: high inside collar faces 3rd speed selector gear.

Fig 9: Determining Thickness Of Circlip

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• Insert circlip for synchronizing hub for 3rd and 4th gear.

• When replacing synchronizing hub or input shaft:

Re-determine thickness of circlip for synchronizing hub for 3rd and 4th gear:

• Determine thickest circlip that will just fit and install it.

The following circlips are available:

• Check axial clearance of 3rd speed selector gear.

Fig 10: Pulling Pin With Clip Securing Selector Fork For 3rd And 4th Gear Out From Selector Rod

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• Slide selector fork for 3rd and 4th gear - C  - together with locking collar - D  - onto selector rod - B  - and synchronizing hub for 3rd and 4th gear.

• The markings on locking collar and synchronizing hub - arrow  - must coincide.

• If the holes of selector fork and selector rod coincide, clip in pin with clip - A  -.