Sequence of Operations For Disassembling and Assembling

Sequence of operations for disassembling and assembling
Disassembling and assembling input shaft ball bearing, multi-function switch, input shaft, pinion shaft, shift rods and transmission cover.

Note:
^To remove the above-mentioned components it is not necessary to remove the differential.
^ Removal is only necessary when adjustment work must be performed.

Special tools, testers and materials
^ Socket 3357
^ Retaining plate VW 309
^ Transmission support VW 353
^ Clamping piece VAG 1582
^ Clamping piece VAG 1582/3
^ Press tool 3235
^ AMV 188 100 02

Disassembling
- Drain transmission oil with socket 3357





- Mount on repair stand.





- Remove clutch release lever -A- with release bearing.
- Remove guide sleeve -B-
- Remove dished washer-C-
- Remove circlip -D- in front of ball bearing.
- Note thickness of circlip -D- if ball bearing, input shaft or transmission housing is not to be replaced.





- Pull input shaft ball bearing out of transmission housing.





- Remove circlip (arrow) behind input shaft ball bearing.
- Note thickness of circlip if ball bearing, input shaft or transmission housing is not to be replaced.





- Unbolt transmission cover -A- from housing -B-.





- Remove bolts (arrows) and pull out multi-function switch.





- Remove relay shaft bolts (arrows)





- Remove bolt (arrow) and swing shift detent out.





- Carefully pull out input shaft -A-, pinion shaft -B-, relay shaft -C-, shift rods and selector shaft -D- and shift forks -E- together.

Assembling
When the input shaft ball bearing, the input shaft or the transmission housing is replaced, the thickness of the circlip for the input shaft must be redetermined. Input Shaft





- Swing transmission housing into position shown.





- Install input shaft -A-, pinion shaft -B-, relay shaft -C-, shift rods and selector shaft -D- and shift forks -E- together.

Note: If necessary, the relay shaft -C- and the shift rod can be installed afterward.





- Turn transmission housing and engage 3rd gear (direction of arrow).





- Install relay shaft-A-.
- Install shift rod -B- sideways onto drilling in housing and assemble into mounting eye.
- Turn shift rod carefully in direction of arrow.





- Install shift detent and fasten with bolt (arrow).





- Install relay shaft bolts (arrows).
- Replace O-ring for multi-function switch.





- Carefully install multi-function switch and tighten (arrows).
- Check that dowel sleeves for transmission cover -A- are installed in housing-B-.





- Install transmission cover -A- onto housing -B-.





- Install rear input shaft ball bearing circlip (arrow).
- Slide ball bearing onto input shaft.
Installation position: the closed side of the ball cage faces the transmission housing.





- Press in ball bearing:
- Slide pressure plate -A- of tool onto input shaft.
- Place tool behind clutch plate splines. Pretension bolts-B- which locate in recesses of pressure plate -A-.
- Press ball bearing in onto stop by alternately tightening the bolts -B- 1/2 turn at a time.





- Install input shaft ball race front circlip -D-.
- Install dished washer-C-.
Installation position: The convex side faces guide sleeve -B-.
- Install release bearing guide sleeve-Be.
- Install clutch release lever -A- and release bearing.