General Repair Information: Components

Front Wheel Drive 

• 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.
• Use the correct bolt allocation.
• Check the transmission fluid level, refer to TRANSMISSION FLUID, CHECKING .
• Fluid capacity and specification, refer to the Maintenance, Diagnosis or Maintenance, Diagnosis .

O-Rings, Seals, Gaskets and Sealant 

• Always thoroughly clean the separating surfaces on the housings before applying the sealant.
• Apply the sealing paste AMV 188 200 03 evenly and not too thick.
• Replace the O-rings, seals and gaskets.
• Flange shaft, input shaft and selector shaft seals areshown in the figure as shaft seals.
• Once a shaft seal or gasket has been removed, check the contact surface on the housing or shaft for burrs and damage caused by the removal. Repair or replace as necessary.
• Before installing the seal, lightly lubricate the outer circumference and fill the space -arrow- between the sealing lips halfway with sealing grease for seal G 052 128 A1.
  Fig 1: Identifying Oil Seal

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side of the seal point toward the fluid to be sealed in.
• Press in the new seal, so that the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• Lightly lubricate O-rings before installing them in order to prevent them from being crushed when installing.
• Check the fluid level in the manual transmission after replacing the seals and O-rings, refer to TRANSMISSION FLUID, CHECKING .

Fasteners 

• Do not overstretch the circlips (lock rings).
• Installed position for some of the lock rings: The lock ring is narrower on top and this shape matches its installed location. This makes it easier for the pliers to grab the lock ring when removing and installing it.
• Always replace damaged or stretched locking rings after removing.
• The lock ring must fit completely inside the groove.
• Replace the roll pins. Installed position: The slit -A- should be in line with the line of force -arrow-.
  Fig 3: Identifying Locking Elements

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolts and Nuts 

• Always loosen or tighten bolts and nuts for covers and housings diagonally and in the opposite direction as the tightening sequence.
• Especially delicate parts, such as the clutch pressure plate, must not be distorted. Loosen and tighten the bolts and nuts in stages and in a diagonal sequence.
• The tightening specification stated applies to non-lubricated nuts and bolts.
• Always replace self-locking nuts and bolts.
• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.
• Use a wire brush to clean the threads on bolts that were installed using locking fluid. Next, use liquid locking fluid AMV 185 101 A1 to install the bolts.
• Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid. 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 tap is used during cleaning, and the threads do not get damaged.
• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.

Bearings 

• Install needle bearings with the lettered side (thicker metal) facing the installation tool.
• Install all the bearings in the transmission using gear oil.
• 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) using the Inductive Heat Unit VAS6414 or equivalent tool, before installing them. Press on to the stop when installing, so there is no axial clearance.
• Do not interchange outer and inner bearing races with those from other bearing of the same size. The bearings are paired.

Adjusting Shims 

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

Synchronizer Rings 

• Do not interchange them. When reusing synchronizer rings, always install them to the same gear.
• Check for wear and replace as necessary.
• Check the grooves -arrow 1- on the synchronizer ring -A- and the inner race for flat areas (grooves are worn).
  Fig 6: Checking Synchronizer Rings For Wear

  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 outer friction surface -arrow 2- and the inner friction surface -arrow 3- for "grooves" or "scoring".
• Check the taper of the drive gear for "grooves" or "scoring".
• Coat the synchronizer ring with transmission fluid and then install it.

Gears, Synchronizer Hubs and Needle Bearing Sleeves 

• Heat the needle bearing sleeve to approximately 100 °C (212 °F) using the Inductive Heat Unit VAS6414 or equivalent tool.
• Heat the synchronizer hub to approximately 100 °C (212 °F) using the Inductive Heat Unit VAS6414 or equivalent tool, before installing it. Press it on as far as the stop when installing it so there is no axial play.
• Heat the gears to approximately 100 °C (212 °F) using the Inductive Heat Unit VAS6414 or equivalent tool, before installing. Press it on to the stop when installing it, so there is no axial clearance.
• Pay attention to the installed location.

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 its bolts diagonally and in small steps.
• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing and the flywheel running surface with a clean cloth.