General Repair Information

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

Troubleshooting 

-- Refer to GENERAL INFORMATION

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.
• For the correct bolts and other components,

For the correct capacities, refer to CODE LETTERS, TRANSMISSION ALLOCATION AND CAPACITIES .

Fill the transmission fluid when repairing the manual transmission.

Gaskets, O-rings and Seals 

• Clean the housing separating surfaces thoroughly before applying the sealant.
• Apply the sealant AMV 188 200 03 evenly and not too thick.
• Replace the O-rings, seals and gaskets.
• After removing gaskets, examine contact surface on housing/shaft for burr 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 the sealing lips -arrow- halfway with grease G 052 128 A1.
  Fig 1: Locating Oil Seal Sealing Lip

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
• The open side of the seals point toward the fluid to be sealed in.
• When installing the new shaft seals, make sure 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 to prevent them from being crushed when inserting.

After replacing the seals, check the transmission fluid level and fill if necessary, refer to TRANSMISSION FLUID, CHECKING, DRAINING AND FILLING .

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.
• Do not allow any sealing paste to get into the ventilation holes.

Fasteners 

• Do not overstretch the circlips.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: the slit -A- should align with the line of force -arrow-.
  Fig 2: Identifying Locking Elements

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolts and Nuts 

• Loosen the bolts and nuts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.
• 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 non-oiled nuts and bolts.
• Always replace self-locking nuts and bolts.
• Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Next, use locking compound 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 there is a risk that the bolts will shear the next time they are removed.

Bearings 

• Install needle bearings with lettered side (thicker metal) racing the fitting tool.
• Insert all the bearings in transmission with gear oil.
• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.
• To install, heat the bearing inner races to approximately 100° C (212° F) with inductive heat unit VAS6414.
• 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 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 wheel.
• 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 5: 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 and scoring.
• Check taper of drive gear for grooves and scoring.
• Coat the synchronizing with transmission fluid and then install.

Gears 

• Warm the needle bearing inner races to approximately 100° C (212° F) with an inductive heat unit VAS6414.
• Heat the synchronizer hub to approximately 100° C (212° F) with the inductive heat unit VAS6414 before installing. Press on as far as the stop when installing so there is no axial play.
• Heat the gears to approximately 100 °C with the inductive heat unit VAS6414 before installing. Press on to the stop when installing, so there is no axial clearance.
• Pay attention to the installed location.

Selector Gears 

• After installing, check 1st through 6th gear for minimal amount of axial clearance and for ease of movement.

Clutch 

• When removing transmission, remove the clutch slave cylinder without opening the lines.
• If the clutch slave cylinder is removed with the hydraulic line attached, do not depress clutch pedal. Otherwise the piston will be pressed out of the clutch slave cylinder.
• Do not tilt the clutch pressure plate. Loosen and tighten it 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.