5 Spd. Manual Transmission 012 and 01W Front Wheel Drive

2005 Audi A4 Quattro
TRANSMISSION 5 Spd. Manual Transmission 012/01W Front Wheel Drive
TRANSMISSION
5 Spd. Manual Transmission 012/01W Front Wheel Drive
00 GENERAL, TECHNICAL DATA

TRANSMISSION, IDENTIFICATION
Transmission, identification
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Fig. 1: Locating Transmission Identification And Date Of Construction
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Location on transmission
Code letters and date of manufacture (arrow 1)
Manual transmission 012 / 01W (arrow 2)
Fig. 2: Manual Transmission 012/01W/0A9

Manual transmission 012 / 01W (arrow 2)
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Fig. 3: Code Letters And Date Of Manufacture

Code letters and date of manufacture (arrow 1)
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Example: ENN 15 11 0
I I I I
I I I I
Code Day Month Year (2000)
letters of production
Additional data are production-related
NOTE: The code letters of the transmission are also given on the vehicle data plates.
Code letters, application, ratios, capacities
Manual transmission 5-speed 012 / 01W

Code letters ENN FPS
Production from 09.00 07.01
to
Application Model Audi A4 2002 > Audi A4 2002 >
Engine 1.8 l - 125 kW 1.8 l - 125 kW
Ratio: Z2 : Z1 Final drive 37 : 10 = 3.700 37 : 10 = 3.700
1st gear 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 37 : 17 = 2.176 37 : 17 = 2.176
3rd gear 40 : 28 = 1.429 40 : 28 = 1.429
4th gear 36 : 33 = 1.091 36 : 33 = 1.091
5th gear 32 : 37 = 0.865 32 : 37 = 0.865
6th gear - -
Reverse gear 31 : 9 = 3.444 31 : 9 = 3.444
Speedometer electronic electronic
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Code letters ENN FPS

Capacity 2.25 liters
Specification Gear oil G 052 911 A 1 SAE 75 W 90 (synthetic oil)
Clutch mechanism hydraulic hydraulic
Clutch plate diameter 228 mm 228 mm
Drive shaft flange diameter 75.5 mm 881) mm
Overall ratio in top gear 3.200 3.200
1) Drive axle with triple rotor joint.
TRANSMISSION LAYOUT
Transmission layout
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Fig. 4: Power Transfer, Overview
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Designation
1 - Engine
2 - Clutch
3 - Manual transmission
4 - Input shaft
5 - Drive pinion (output shaft)
6 - Differential
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NOTE: Arrows face in direction of travel.
Ratio
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
NOTE: Arrows face in direction of travel.
CALCULATIONS
Calculating transmission ratios "i"
Transmission ratio
Transmission ratio = No. of teeth on : No. of teeth on drive

driven gear gear
Ratios Formula
iG = Gear ratio ZG2 : ZG1
iA = Axle ratio ZA2 : ZA1
itotal = Overall ratio iG x iA
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Example:
5th gear Final drive
Drive gear ZG1 = 37 ZA1 = 9
Driven gear ZG2 = 31 ZA2 = 35
Calculations:
iG = 31 : 37 = 0.838
iA = 35 : 9 = 3.889
itotal = 0.838 x 3.889 = 3.259
General repair instructions
To make sure of satisfactory and successful transmission repairs the maximum care and cleanliness and proper
tools are essential. When carrying out vehicle repairs basic safety precautions apply.
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A number of general instructions for individual repair operations, which are otherwise mentioned at various
points in the article, are summarized here. They apply to this article.
Special tools
For a complete list of special tools used in this article
Refer to Booklet; Special tools, Workshop equipment
Transmission
 Select the correct bolts and other components according to the transmission code letters. Refer to Code
letters, application, ratios, capacities.
 When installing a new transmission, the oil level must be checked and oil added. Refer to Oil level in
manual transmission, checking.
 Capacities and specifications. Refer to Code letters, application, ratios, capacities.
 Carefully clean all joints and adjacent areas before disconnecting.
 When installing transmission, make sure that the dowel sleeves are installed correctly.
Sealants
 Thoroughly clean housing joint surfaces before applying sealing paste.

 Apply sealing paste AMV 188 001 02 evenly and not too thick.
 Breather holes must remain free of sealing paste.
O-rings, seals, gaskets
 Always replace O-rings, seals and gaskets.
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 Always inspect the contact surface on the housing or shaft for burrs or other signs of damage resulting
from removal of gaskets and seals.
 Thoroughly clean housing joint surfaces before assembling.
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Fig. 5: Identifying Space Between Oil Seal Sealing Lips
 Before installing radial shaft oil seals, lubricate outer diameter slightly and half fill space between sealing
lips -arrow- with sealing grease G 052 128 A1.
 Open side of the seal faces toward the side containing the oil.
 When replacing oil seals, the point at which the sealing lips make contact vary (use insertion depth
tolerances).
 Lightly lubricate O-rings before installing. This prevents them from being damaged when assembling.
 Check oil level in transmission after replacing seals and gaskets. Refer to Oil level in manual
transmission, checking.
Locking elements
 Do not over-stretch circlips.

 Always replace circlips which been damaged or over-tightened.
 Circlips must be seated in the base of the groove.
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Fig. 6: Identifying Locking Elements
 Replace spring sleeves. Installation position: Slot -A- longitudinal to line of force -arrow-.
Nuts, bolts
 Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
 Tighten and loosen nuts and bolts for securing covers and housings in a diagonal sequence.
 Take care not to tilt particularly sensitive components, such as clutch pressure plates, loosen and tighten
nuts and bolts gradually in a diagonal sequence.
 The tightening torques stated apply to non-oiled nuts and bolts.
 Always replace self-locking nuts and bolts.

 Clean threads of bolts using a wire brush with a locking compound screw in. Then apply AMV 185 101
A1 when inserting.
 Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be
cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.
Bearings
 Install needle bearings with the lettering on the bearing (the side with thicker metal) facing toward the
drift or other tool used for installing.
 Mark the needle roller bearings on 1st to 5th speed sliding gears when removing. Make sure the needle
roller bearings are in the same position when re-installing.
 Grease needle roller bearing for transmission input shaft in flywheel.
 Lubricate all bearings in transmission housing with gear oil before installing.
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 Heat inner races of tapered roller bearings to approx. 100 ° C before installing. Press fully up to stop free
of axial play when installing.
 Do not interchange the outer or inner races of bearings of the same size. The bearings are paired.
 Always replace the tapered roller bearings on one shaft together and use new bearings from a single
manufacturer.
 The tapered roller bearings for the output shaft and the differential in the transmission are low-friction
bearings. Do not add oil to new tapered roller bearings when measuring friction torque. The bearings are
pre-treated at the factory with a special type of oil for this purpose.
Shims
 Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain
exact shim thickness required.
 Check for burrs and damage. Install shims which are in perfect condition.
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Sliding gears
 After installing, check that 1st to 5th speed sliding gears have axial play of 0.15... 0.35 mm and move
freely.
Synchronizer rings
 Do not interchange synchronizer rings. When reusing always install the same gear.
 Check for wear, replace if necessary.
 Coat with gear oil when installing.
Gears, synchro-hubs, inner races for sliding gears
 Heat gears and synchro-hubs to approx. 100 ° C before installing. When installing press fully up to stop
free of axial play.
 Heat inner races for sliding gears to approx. 100 ° C when installing.
 Temperature can be checked with temperature tester V.A.G 1558.
 Note installation position.
Clutch mechanism
 When removing transmission, remove clutch slave cylinder without disconnecting pipes.
 Do not depress the clutch pedal after removing the slave cylinder if the hydraulic line is still connected.
Otherwise the piston will be pressed out of the slave cylinder.
 Make sure clutch pressure plate is kept straight; loosen and tighten bolts gradually in diagonal sequence.
 To reduce the odor of the burnt clutch, thoroughly clean the bell housing, flywheel and parts of the engine
facing the transmission.
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30 CLUTCH
CLUTCH MECHANISM, SERVICING
Clutch mechanism, servicing
Fig. 7: Clutch Mechanism, Servicing - Pedal Cluster And Hydraulic System

Courtesy of VOLKSWAGEN UNITED STATES, INC. cardiagn.com
I - Exploded view of pedal cluster. Refer to Pedal cluster, assembly overview
II - Exploded view of hydraulic system. Refer to Hydraulic system, assembly overview
NOTE:  Note or obtain radio code on vehicles with coded radio.

 Disconnect battery ground strap with the ignition switched off.
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 Lubricate all bearings and contact surfaces with polycarbamide grease G

052 142 A 2.
CAUTION: On vehicles equipped with Audi Telematics by OnStar ® , switch-off the

emergency (back-up) battery for the Telematic/Telephone Control Module
prior to disconnecting the vehicle battery. Switch-on the emergency (back-
up) battery after reconnecting the vehicle battery. Refer to
 91 - COMMUNICATION
 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for
Cabriolet
 Remove cover below instrument panel, before working on foot pedal cluster
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Refer to
 68 - INTERIOR EQUIPMENT
 68 - INTERIOR EQUIPMENT for Cabriolet
 Make sure brake fluid does not escape into footwell or plenum chamber or onto transmission below. If
this does happen, clean the affected areas thoroughly.
 Protect the carpet from brake fluid using rags, when performing work in the footwell.
Pedal cluster, assembly overview
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Fig. 8: Pedal Cluster, Assembly Overview
1 - Mounting bracket
 Removing and installing. Refer to Slave cylinder, removing and installing
2 - Fulcrum pin for clutch and brake pedal
3 - Fastener
4 - Hex socket-head bolt - 25 Nm
5 - Brake pedal
 Mounting is maintenance-free, do not grease
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6 - Clutch pedal switch
 Can only be installed one time
 For securing pivot pins for clutch and brake pedal
8 - Clutch pedal
9 - Fastener
10 - Retainer
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 Removing and installing. Refer to Hydraulic system, assembly overview
12 - Master cylinder

 Seal -arrow- must not be removed
13 - Over-center spring
 Black end points toward clutch pedal

 Removing and installing. Refer to Over-center spring, removing and installing
 Allocation
Refer to Parts list
14 - Clutch Pedal Position (CPP) Switch -F194-
 Can only be installed one time
15 - Torx bolt - 25 Nm
 For securing brake master cylinder/brake servo to mounting bracket
Over-center spring, removing and installing
Special tools and workshop equipment required
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Fig. 9: T40025 Installation Clamp

 T40025 Installation clamp
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Removing
 Remove driver's storage compartment:
Refer to
Fig. 10: Installation Clamp T40025 Installed On Over-Center Spring

 Tension over-center spring with clutch pedal and press on installation clamp T40025.
 Bring clutch pedal to rest position and take out over-center with spring and installation clamp T40025
from below.
Installing
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 Pull clutch pedal into passenger compartment.
Installation position over-center spring:
 Black end over-center spring points toward clutch pedal.
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Fig. 11: Installation Clamp T40025 Installed On Over-Center Spring
 Insert over-center spring with installation clamp T40025, depress clutch pedal and pull out installation
clamp.
Hydraulic system, assembly overview
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Fig. 12: Hydraulic System, Assembly Overview
1 - Brake fluid reservoir
2 - Supply hose
 For master cylinder
3 - Hose assembly
 For plug-in connections on master/slave cylinder

 Separating from master cylinder and installing. Refer to Slave cylinder, removing and installing
 Separating from slave cylinder. See Separating slave cylinder from hose and pipe assembly
4 - Grommet
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5 - Mounting bracket
6 - Clutch pedal
7 - Master cylinder

 Clip (arrow A) and seal (arrow B) must not be removed
 To remove hose/pipe assembly, pull clip (arrow A) out up to stop. Refer to Fig. 27
9 - Retainer
 Replace only with master cylinder removed
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 Removing. See Pulling off retainer
 Pressing on. See Pressing master cylinder operating rod into retainer
10 - Transmission
11 - Slave cylinder
 Do not operate clutch pedal after slave cylinder has been removed.
 Removing and installing. Refer to Before installing, coat clutch slave cylinder with grease
 After working on hydraulic clutch mechanism, bleed slave cylinder. Refer to Clutch system, bleeding
 Separating from hose/pipe assembly. See Separating slave cylinder from hose and pipe assembly
 Brake fluid must not come into contact with transmission
12 - Bleeder valve
 Tighten to 4.5 Nm
 Follow correct sequence when bleeding. Refer to Clutch system, bleeding
13 - Dust cap
14 - Clip
 To remove pipe, pull out clip up to stop. Refer to Separating slave cylinder from hose and line
assembly
15 - Bracket
 for hose and line assembly
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 Secured to transmission with slave cylinder
 Slave cylinder to transmission

 Self-locking
 Always replace
17 - Retaining clip
18 - Seal
19 - Securing bolt
 for brake fluid reservoir
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Pulling off retainer
Fig. 13: Removing Retainer By Prying

Pressing master cylinder operating rod into retainer
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Fig. 14: Installing Clutch Master Cylinder Operating Rod In Retainer

Separating slave cylinder from hose and pipe assembly
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Fig. 15: Removing Hydraulic Line From Slave Cylinder
Removing
 Use a screwdriver to remove hose and line assembly, pull out clip -A- up to stop. Then the hose and pipe
assembly can be pulled out.
Installing
 Press in clip -A- up to stop

 Insert hose and pipe assembly into slave cylinder until it is heard to engage.
 Test by pulling on hose and pipe assembly.
Slave cylinder, removing and installing
Special tools, testers and auxiliary items required
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Fig. 16: Identifying Hose Clamps 3094

 3094 Hose clip
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Fig. 17: Identifying Spark Plug Connector Pliers V.A.G 1922
 VAG 1922 Pliers
Removing
 Remove rubber seal from plenum chamber in direction of arrow.
Fig. 18: Removing Cover Over Plenum Chamber

 Remove cover -1- over plenum chamber.

 Check whether an encoded radio is installed. If so, obtain anti-theft code.
CAUTION: On vehicles equipped with Audi Telematics by OnStar ® , switch-off the

emergency (back-up) battery for the Telematic/Telephone Control Module
prior to disconnecting the vehicle battery. Switch-on the emergency (back-
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up) battery after reconnecting the vehicle battery. Refer to
Cabriolet
 Disconnect battery ground strap with ignition switched off.
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Fig. 19: Removing Securing Clips And Cowl
 Use screwdriver to pry off the two caps -3-.

 Remove nuts -4- and detach the two wiper arms -2-.
 Pull off clips -1- and remove cowl panel grille -5-.
Remove electronics box in plenum chamber as follows:
Fig. 20: Electronics Box Sealing Cover

 Screw out bolts -arrows- and pull off sealing cover.
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Fig. 21: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623
 Carefully pry off retainer bar with screwdriver -arrow-.
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Fig. 22: Releasing Connector Latches And Pulling Off Connectors On Engine Control Module
 Release connector latches -arrows- and pull off connectors -1- and -2- on engine control module.
Fig. 23: Connector At Connector Rail And Wire

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 Pull off connector -2- from connector rail

 Disconnect wire -1-.
Fig. 24: Locating Auxiliary Relay Carrier Catches
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 Release catches -arrows- and pull auxiliary relay carrier in electronics box upward to remove.
 Pull engine wiring harness together with rubber grommet out of recess in electronics box.
Fig. 25: Electronics Box Nuts

 Remove nuts -arrows- and lift out electronics box -1-.
NOTE:  Make sure that brake fluid does not escape into the plenum chamber or
onto the transmission below. If this does happen, clean the affected areas
thoroughly.
 Protect the carpet from brake fluid using rags when performing work in the
footwell.
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Fig. 26: Identifying Brake Fluid Reservoir Return Hose Grommet

 Clamp supply hose -A- leading to brake fluid reservoir using special tool 3094. Pull hose off at master
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cylinder and plug it.
 Remove rubber grommet from bulkhead on the supply hose connecting line.
 Use a screwdriver to pry out retaining clip -C- and then pull out line -B- slightly.
Fig. 27: Location Of Brake Fluid Reservoir Dowel Bolt

 Remove bolt from brake fluid reservoir -1- and disconnect connector from fluid level below.
NOTE: Do not remove the brake fluid reservoir.
NOTE:  For ease of illustration, brake fluid reservoir is not shown.

 To remove the top Torx bolt, swivel brake fluid reservoir slightly to one
side.
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Fig. 28: Location Of Brake Servo Securing Bolts

 Remove the two Torx bolts -arrows-.
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 Remove vacuum line from brake servo -1-.
 Remove driver's side storage compartment.
Refer to
Fig. 29: Brake Pedal At Brake Servo

 Detach brake pedal from brake servo.
Refer to 47 - BRAKES - HYDRAULIC COMPONENTS
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Fig. 30: Locating Steering Column At Steering Gear And Disconnecting Connector On Clutch Pedal
Switch, Brake Pedal Switch And On Accelerator Pedal Module
 Disconnect steering column from steering gear -arrow A-.
Refer to 48 - STEERING
 Disconnect connector on clutch pedal switch -1-, brake pedal switch -2- and on accelerator pedal module
-3-.
 Remove securing bolt from mounting bracket -arrow B- and complete pedal cluster.
Release master cylinder operating rod from clutch pedal as follows:
 Removing over-center spring. Refer to Over-center spring, removing and installing.
NOTE:  Make sure a tight connection in the clutch pedal switch. Refer to Pedal
cluster, assembly overview Pos. 6 as well as the Clutch Pedal Position
(CPP) Switch -F194-. Refer to Pedal cluster, assembly overview Pos. 14 in
the pedal cluster, these switches may only be installed once.
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Fig. 31: pressing Retainer Together And Detaching Clutch Pedal From Master Cylinder Using VAG 1922
 When releasing clutch pedal make sure that it does not strike against retainer for clutch pedal switch -
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arrow-. This could break the retainer.
 Insert pliers VAG 1922 into recess of clutch pedal, press retainer together -arrows- and detach clutch
pedal from master cylinder.
Fig. 32: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder
 Remove retaining clip -1- and pull off clutch pedal -2-.
 Remove bolts -3- and detach master cylinder -4-.
Installing
Install in reverse order, paying attention to the following:
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Fig. 33: Identifying Retaining Clip, Clutch Pedal, Bolts And Master Cylinder
 Insert master cylinder and tighten screws -3- to 20 Nm.
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Fig. 34: Locating Mounting Bolts
 Insert retainer -1- into clutch pedal.

 Press clutch pedal in direction of arrow to engage, make sure that retainer -1- is correctly locked in clutch
pedal.
 Install over-center spring. Refer to Over-center spring, removing and installing.
A second mechanic is required for the next step.
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Fig. 35: Location Of Clutch Pedal Switch F36 And Pedal Assembly Securing Bolt
 Insert complete pedal cluster and install bolt -1- hand-tight. The second mechanic must simultaneously
insert line into master cylinder from plenum chamber side.
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Fig. 36: Location Of Brake Servo Securing Bolts
 Tighten bolts for brake servo -arrows- to 25 Nm.
Fig. 37: Installing Rubber Grommet And After-Run Hose
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 Press in retaining clip -C- up to stop.

 Insert line -B- into master cylinder until it is heard to engage.
 Insert rubber grommet -D- over supply hose connecting line -A- into bulkhead.
 Slide supply hose -A- for the brake fluid reservoir up to stop.
 Remove special tool 3094.

 Install bolt for brake fluid reservoir.
 Tighten hex socket-head bolt for securing pedal cluster on instrument panel support to 25 Nm.
 Plug in connectors.
 Connect brake pedal to brake servo.
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 Secure steering column to steering gear -arrow A-.
Refer to 48 - STEERING
 Installing driver's storage compartment:
Refer to
 Bleed clutch system. Refer to Clutch system, bleeding.
Fig. 38: Electronics Box Nuts

 Insert electronics box and tighten nuts -arrows- to 4 Nm.
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 Route engine wiring harness and connect connectors to connector point.

 Install engine control module and if applicable auxiliary relay carrier with auxiliary fuse carrier.
Refer to 97 WIRING
 Press on sealing cover hand-tight and tighten screws in diagonal sequence to 4 Nm.
NOTE:  On re-connecting battery, remember to check and re-activate vehicle

equipment (radio, clock, convenience electronics, etc.).
Refer to
 01 - MAINTENANCE
 01 - MAINTENANCE for Cabriolet
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Clutch system, bleeding
Fig. 39: Identifying Brake Filler And Bleeder Unit VAS 5234
 Brake filling and bleeding unit VAS 5234
 Brake fluid specification
NOTE:  Open bleed valve before switching on bleeding appliance.

 When performing the following steps, make sure that no brake fluid
escapes onto the transmission.
 Performing work on the hydraulic clutch mechanism the clutch system
must be bled.
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 Pull out clutch pedal and fill brake fluid reservoir with brake fluid up to
"max." mark before bleeding.
 Connect brake filling and bleeding unit VAS 5234, but do not turn on at this time.
 If installed, remove noise insulation beneath transmission.
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Fig. 40: Connecting Bleeder Hose To Clutch Slave Cylinder
 Connect bleeder hose -A- to slave cylinder (arrow) and open bleeder valve.
 Connect bleed hose to pressure hose of collector bottle.
 Switch on bleeding appliance and allow about 100 cm3 of brake fluid to flow out.
 Working pressure 2.5 bar
NOTE: Make sure bleed hose is correctly installed during bleeding operation.
 Tighten bleed valve to 4.5 Nm.

 Depress clutch pedal several times after bleeding process.
 Bleed again if necessary.
CLUTCH RELEASE MECHANISM, SERVICING
Clutch release mechanism, servicing
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Fig. 41: Clutch Release Mechanism, Overview
1 - Slave cylinder
 Do not operate clutch pedal after slave cylinder has been removed.
 Separating from hose and line assembly. See Separating slave cylinder from hose and line assembly
 Installing. See Before installing, coat clutch slave cylinder with grease and . Installing clutch slave
cylinder
 When installing, press in slave cylinder far enough so that securing bolt can be installed easily.
 Tighten bleed valve to 4.5 Nm

 Bleeding clutch system. Refer to Clutch system, bleeding
2 - Hex socket-head bolt, 23 Nm
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 Slave cylinder to transmission

 Self-locking
 Always replace
3 - Bracket
 For hose and line assembly

 Secured to transmission with slave cylinder
 Installing. See Installing clutch slave cylinder
4 - Push rod
 Lubricate end of push rod with copper grease, e.g. Z 381 351 TE
5 - Dished washer
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 Smaller diameter (convex side) to guide sleeve
6 - Input shaft oil seal
 Available with guide sleeve -Item 11- Clutch release mechanism, servicing as replacement part
7 - Torx socket head bolt
 Self-locking
 Always replace
 Black; only for aluminum transmission
 Allocation
 On aluminum transmission tighten to 35 Nm
8 - Release bearing
 With or without plastic ring depending on design. See Servicing release bearing with plastic ring
 Adhering detached plastic ring. See Servicing release bearing with plastic ring
 Do not wash out bearing, only wipe
 Replace noisy bearings
 Allow retaining lugs on release bearing to engage in release lever
9 - Clutch release lever
 Coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381 351 TE before
installing
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10 - Retaining spring
 Secure to clutch release lever
11 - Guide sleeve
 Available with oil seal -Item 6- Clutch release mechanism, servicing as replacement part
 Installation position: Oil drain hole points downward
 Cover input shaft splines with a shrink-fit hose to protect oil seal -Item 6- Clutch release mechanism,
servicing before removing and installing
12 - O-ring
 Always replace
13 - Intermediate piece
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14 - Ball stud
 Lubricate with MoS2-grease

 On aluminum transmissions tighten to 25 Nm
Separating slave cylinder from hose and line assembly
Fig. 42: Removing Hydraulic Line From Slave Cylinder

Removing
 Use a screwdriver to remove hose and line assembly, pry out clip -A- up to stop. Then pulled out the hose
and line assembly.
Installing
 Press in clip -A- up to stop
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 Insert hose and line assembly into slave cylinder until it is heard to engage.
 Test by pulling on hose and line assembly.
Before installing, coat clutch slave cylinder with grease
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Fig. 43: Coat Boot Area Of Clutch Slave Cylinder With Lithium Grease
 Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351
TE.
 Lubricate area -a- on boot with lithium grease G 052 150 A2 before fitting slave cylinder into
transmission housing.
Installing clutch slave cylinder
Fig. 44: Clutch Slave Cylinder, Bracket And Hose/Line Assembly

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 Fasten bracket for hose line assembly -3- onto slave cylinder -4- and bolt together slave cylinder to
transmission.
 Insert the clutch slave cylinder into the mounting hole of the transmission housing, keep it in line with the
direction of operation of the push rod.
NOTE:  There is a danger that the push rod will be guided past the clutch release
lever if the clutch slave cylinder -4- is inserted off-line.
 Press in the clutch slave cylinder far enough so that the securing bolt can
be fitted easily.
 Replace securing bolt - 2-.
Servicing release bearing with plastic ring
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Fig. 45: Servicing Release Bearing With Plastic Ring
On release bearings with plastic ring it is possible that the plastic ring detaches from the release bearing
during removal of transmission or release bearing; this is not a reason for replacing release bearing.
 Adhere plastic ring back onto bearing ring with adhesive AMV 195 KD1 01 before installing
transmission.
Three right-angled lugs -arrows- on plastic ring engage in the recesses of bearing ring.
NOTE: The release bearing must be replaced if the plastic ring lies deeper than 0.5 mm
on the contact surface.
CLUTCH, SERVICING
Clutch, servicing
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Fig. 46: Identifying Special Tools - Clutch, Servicing
 3067 Flywheel retainer

 3176 Centering mandrel
 VAG 1331 Torque wrench
NOTE:  Observe the general repair instructions. Refer to General repair

instructions.
 Replace clutch plates and pressure plates with damaged or loose rivets.
 Select the correct clutch plate and pressure plate according to engine
code:
2:14:20 AM Page 37
 Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and
apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate on input shaft
until hub moves freely on shaft. Excess grease must be removed.
 Pressure plates are protected against corrosion and are greased. Only the contact surface may be cleaned,
otherwise the service life of the clutch will be reduced.
 If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the
transmission to reduce the smell of burnt linings.
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Fig. 47: Clutch Remove/Install Components
 Remove transmission to work on clutch. Refer to Transmission, removing and installing.
A - Colored marking on dual mass flywheel
 If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -
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B- on pressure plate.
B - Colored marking on pressure plate
 If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -
B- on pressure plate.
1 - Flywheel/dual mass flywheel
 Make sure that centering pins are a tight fit

 Contact surface for clutch lining must be free of grooves, oil and grease
 Removing and installing. Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
2 - Bolt for flywheel
Always replace
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
 Vehicles without dual mass flywheel 60 Nm + turn 90 ° further

 Vehicles with dual mass flywheel
 Bolt length 22 mm 60 Nm + turn 90 ° further

 Bolt length 42 mm 60 Nm + turn 180 ° further
3 - Clutch plate
 Installation position:
 Spring pack (coil springs) toward pressure plate and transmission

 Clutch lining must make full contact with flywheel
 Marking "Getriebeseite" (if present) goes toward pressure plate and transmission
 Do not grease
 Clutch plate diameter. Refer to Code letters, application, ratios, capacitiesonward
 Centering. See Centering clutch plate and removing and installing pressure plate
 Lightly grease splines
4 - Pressure plate
 Removing and installing. See Centering clutch plate and removing and installing pressure plate
 Check ends of diaphragm spring. See Checking ends of diaphragm spring
 Checking spring connection and riveted fastenings. See Checking spring connection and riveted
fastenings
 If components are marked, assemble with white marking on flywheel -A- aligning with white marking on
pressure plate -B-.
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5 - Bolt, 25 Nm
 Loosen and tighten gradually over several stages in diagonal sequence
6 - Needle bearing
 Removing and installing:
Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
Centering clutch plate and removing and installing pressure plate
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Fig. 48: Centering Clutch Plate And Removing And Installing Pressure Plate
 Loosen and tighten bolts gradually over several stages in diagonal sequence - 25 Nm.
 Reverse position of counterhold 3067 when removing.
 Installation position of clutch plate: Spring pack (coil springs) or marking "Getriebeseite" toward pressure
plate and transmission.
 Do not insert mounting bolts until clutch lining and contact surface of pressure plate must make full
contact with flywheel.
 Use mandrel 3176 to center clutch plate.

 If components are marked, assemble with white marking on dual-mass flywheel -A- aligning with white
marking on pressure plate -B-.
Checking ends of diaphragm spring
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Fig. 49: Checking Ends Of Diaphragm Spring

 Wear up to half the thickness of the diaphragm spring is permitted.
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NOTE: When performing repairs always match up clutch pressure plate and clutch
plate by checking engine code.
Checking spring connection and riveted fastenings
Fig. 50: Checking Spring Connections And Rivet Connections

 Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are
seated tightly.
 Replace clutches with damaged springs or loose riveted fastenings -arrows-.
34 MANUAL TRANSMISSION - CONTROLS, HOUSING

SHIFT MECHANISM, SERVICING
Shift mechanism, servicing
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NOTE: Before working on the selector mechanism, disconnect the Ground strap from
the battery in the engine compartment.
CAUTION: Before beginning repairs on the electrical system:
 Obtain the anti-theft radio security code.

 Switch the ignition off.
 Disconnect the battery Ground (GND) strap.
 On vehicles equipped with Audi Telematics by OnStar ® , switch-off
the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery. Refer to

Cabriolet
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.
 After reconnecting vehicle battery, re-code and check operation of

anti-theft radio. Also check operation of clock and power windows
according to article and/or Owner's Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar ® , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module. Refer to

Cabriolet
.
Installation position of gear selector mechanism
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Fig. 51: Installation Position Of Gear Selector Mechanism
1 - Selector rod
2 - Front push rod
3 - Gear selector lever
Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
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Fig. 52: Shift Lever Knob And Protective Boot Remove/Install Components, Shift Lever And - Rear Push
Rod And Shift Lever And - Front Push Rod
I - Removing and installing shift lever knob and protective boot. Refer to Shift lever knob and protective
boot, removing and installing
II - Servicing shift lever and - rear push rod. Refer to Shift lever and rear push rod, servicing
III - Servicing shift lever and - front push rod. Refer to Selector rod and front push rod, servicing
Removing and installing selector mechanism. Refer to Shift mechanism, removing and installing
Adjusting gear selector mechanism. Refer to Shift mechanism, adjusting
Shift lever knob and protective boot, removing and installing
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Fig. 53: Shift Lever Knob And Protective Boot Remove/Install Components
1 - Shift lever knob
 Remove and install together with protective boot

 Removing. Refer to Fig. 57
2 - Protective boot
 Remove and install together with shift lever knob

3 - Connector piece
 For locking shift lever knob to shift lever
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 Opening catch. Refer to Fig. 58

 Connects protective boot to shift lever knob
4 - Cover for center console
 Removing and installing. Refer to Fig. 57
5 - Damping washer
 Installation position: Convex side upward
6 - Noise insulation
 Installation position: Arrow on noise insulation points in direction of travel
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7 - Hex nut, 10 Nm
9 - Hex nut, 10 Nm
10 - Shift lever
 Removing and installing. Refer to Shift mechanism, removing and installing
Shift lever and rear push rod, servicing
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Fig. 54: Shift Lever And Rear Push Rod Remove/Install Components
NOTE: Lubricate mountings and sliding surfaces with polycarbamide grease, part no.
G 052 142 A2.
1 - Shift lever
 Lubricate area around bottom hole with G 052 142 A2

 Lubricate ball with G 052 142 A2 polycarbamide grease
2 - Spacer tube
 Lubricate with G 052 142 A2 polycarbamide grease
3 - Circlip
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 Always replace
4 - Washer
 Collar faces ball guide (item 6 Shift lever and rear push rod, servicing)
5 - Rubber ring
6 - Ball guide
 Removing and installing. Refer to Shift lever with rear push rod, removing and installing
7 - Rubber ring
8 - Rear push rod
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 With ball housing
9 - Bolt, 6 Nm
 Qty. 4
 For rear push rod - to shift lever housing
Selector rod and front push rod, servicing
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Fig. 55: Shift Rod And Pivot Rod, Overview
1 - Rear push rod
2 - Bolt, 6 Nm
 Qty. 4
4 - Washer
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6 - Clamp
7 - Hex nut, 10 Nm
 Qty. 4
 For shift lever housing to body
8 - Hex nut, 10 Nm
 Self-locking
 Always replace
9 - Shift lever
10 - Spacer tube
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11 - Selector fork
12 - Bolt
13 - Shift lever housing
14 - Tensioning ring
15 - Bellows
 Remove catalytic converter and front heat shield before removing and installing
NOTE:  Carefully pull boot over selector rod

 Place boot on markings of selector rod and push rod
16 - Selector rod
 With selector joint
17 - Bolt, 23 Nm
 Self-locking
 Always replace
 Cannot be removed from bearing bushing on front push rod
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19 - Front push rod
Shift lever with rear push rod, removing and installing
Removing
NOTE: The shift lever knob is removed together with shift lever cover and cover for
center console.
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Fig. 56: Lifting Cover For Center Console Upward
 Lift cover for center console upward -arrows-.
Fig. 57: Releasing Connector Piece

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 Release connector piece -1- in direction of arrow and pull off shift lever knob together with shift lever
cover upward.
Fig. 58: Lifting Cover And Pulling Out And Removing Bolts And Pulling Ashtray From Center Console
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 Lift cover off -1- first in direction of arrow -A- and then pull out in direction of arrow -B-.
 Remove bolts -arrows C- and then pull ashtray -2- from center console
Fig. 59: Lifting Out Damping Washer And Noise Insulation

 Lift out damping washer -1- and noise insulation -2-.
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Fig. 60: Locating Noise Insulation For Shift Lever Housing Bolts
 Remove noise insulation for shift lever housing -arrows-.
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Fig. 61: Locating Securing Nuts For Shift Lever Housing
 Remove securing nuts -arrows- for shift lever housing.
This lowers the shift lever housing.
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Fig. 62: Shift Mechanism Housing Fasteners

 Detach push rod, by removing hex socket -head bolt -2-.

 Remove selector rod, by removing hex socket -head bolt -3-.
 Detach complete rear push rod - from shift lever housing -arrows-.
 Remove shift lever with rear push rod - from shift lever housing.
Installing
Installation is carried out in the reverse order of removal, note the following:
 Adjust gear selector mechanism. Refer to Shift mechanism, adjusting.
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Fig. 63: Turning Connector Piece Till It Stops
 Place shift lever knob together with shift lever cover onto shift lever and turn connector piece -1- in
direction of arrow till it stops.
Tightening torques
Rear push rod - to shift lever housing 6 Nm

Selector rod to selector fork/shift lever 25 Nm
Front push rod to rear push rod 25 Nm
Shift lever housing to body 10 Nm
Cover to rear push rod 10 Nm
Shift mechanism, removing and installing
Removing
NOTE: The shift lever knob is removed with shift lever cover and cover for center
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console.

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 Lift off cover for center console upward -arrows-.

cover upward.
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 Remove securing nuts for shift lever housing -arrows-.
Fig. 70: Locating Covers Bolts

 Remove bolts -arrows- and detach covers -1- and -2-.
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Fig. 71: Cross Member Bolts

 Remove rear cross member -arrows-.
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Fig. 72: Rear Section Of Exhaust System And Front Cross Member
 Remove front cross member -1- -arrows-.

 Remove rear section of exhaust system (rearward of exhaust pipe clamp(s) -2-:
Refer to 26 - EXHAUST SYSTEM, EMISSION CONTROLS
 Remove heat shield -4- above exhaust system.
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Fig. 73: Identifying Transmission Shift And Pivot Rods

 Remove selector rod -arrow A-.
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 Remove hex socket-head bolt of push rod -arrow B-.
 Swivel shift lever housing with selector rod and push rod downward and remove.
Installing
Installation is carried out in the reverse order.
 Push selector rod on so the securing bolt fits in the recess of the selector shaft.

 Tighten screw selector rod (arrow -A-).

 Push rod must be screwed to transmission (arrow -B-).
 Align exhaust system stress-free:
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direction of arrow as far as stop.
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Tightening torques
Component Nm
Shift lever housing to body 10
Selector rod to transmission 23
Push rod to transmission 40
Clamp for exhaust pipe 40
Front cross member 55
Rear cross member 55
Noise insulation for shift lever housing to rear push rod 10 Nm
Shift mechanism, adjusting
NOTE: The following are prerequisites for correct shift linkage adjustment:
 Perfect shift linkage operating and transfer elements.

 Shift selector mechanism moves smoothly.
 Transmission, clutch and clutch mechanism must be in good condition.
 Transmission in neutral.
Removing
NOTE: Remove the shift lever knob with shift lever cover and cover for center console.
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cover upward.
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 Lift off trim -1- first in direction of arrow -A- and then pull out in direction of arrow -B-.
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 Lift up damping washer -1- and noise insulation -2- upward.
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 Remove noise insulation from shift lever housing -arrows-.

 Measure distance -a- between the two studs in shift mechanism
NOTE: Measurement is from center of stud to center of stud.
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Fig. 81: Shift Mechanism Measurement And Bolts
 Specification: Dimension a = 85 mm
 In case of deviation, adjust distance -a- as follows:

 Loosen bolt (arrow) for push rod.
 The rear push rod (in shift mechanism) must move back and forth easily on slide.
 Adjust measurement -a- by moving rear push rod (in shift mechanism).
 Tighten bolts for push rod -arrow- to 25 Nm.
Fig. 82: Selector Rod Bolt

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 Remove bolts for selector rod -arrow-.
 The selector rod and shift mechanism connection must move freely
Align shift lever as follows:
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Fig. 83: Centering Bottom Of Shift Lever Centered In Ball Housing
 Center bottom of shift lever centered in ball housing.
 The distance from ball housing to bottom of shift lever -arrows- must be same at all points.
 Shift lever stands vertical in direction of travel.
 Hold shift lever in this position.

 Tighten bolt for selector rod -arrow- to 25 Nm.
NOTE: The shift lever must remain in the same position while the bolt is being
tightened.
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 Install covers and shift lever knob.
Shift lever alignment, checking
 The shift lever must rest in the 3rd/4th gear gate when the transmission is in neutral.
 Depress clutch.
 Check that all gears can be engaged.
 The shift lever must not make contact with cover for center console when selecting gears.
 The shift lever should return by itself from the 5th/reverse gear gate into the 3rd/4th gear gate.
 It should only be possible to engage reverse gear from neutral when shift lever is in 3rd/4th gear gate.
 It must be impossible to change from 5th gear directly into reverse gear.
NOTE: If only 5th and reverse gear cannot be engaged, the 5th and reverse gear
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locking module must be checked and replaced. Refer to Removing and
installing locking module for 5th gear and reverse gear.
TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing
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Fig. 85: Identifying Special Tools - Transmission, Removing And Installing
 3282 Transmission support

 3282/10 Adjustment plate
 VAG 1383 A Engine/transmission lifter
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Fig. 86: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
 10-222A Engine support bridge
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Removing
 Read battery CAUTION! note. Refer to Shift mechanism, servicing.

 Note or obtain radio code on vehicles with coded radio.
 Disconnect battery ground strap with the ignition switched off.
Fig. 87: Removing Engine Cover

 Remove engine cover (arrows).
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Fig. 88: Support Bar 10-222 A With Supports 10-222 A/1 Installed On Engine
 Fit support bar 10-222 A with supports 10-222 A/1.
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 Tighten engine slightly using the spindles.
All models:
Fig. 89: Removing Sound Insulation

 Detach noise insulation -arrows-.
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Fig. 90: Removing Noise Insulation Bracket

 Remove bracket for noise insulation -arrow-.
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2:14:21 AM Page 69
 Remove tunnel cross member -1- -arrows-.
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Fig. 93: Detaching Heat Shields And Right-Hand Axle Shaft
 Remove bolts -arrow 1- and -arrow 2- above the right drive shaft and remove heat shield.
 If installed, remove heat shield above the left drive shaft.
Vehicles with 4-cylinder engine:
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 Remove front exhaust pipe -3- from clamp -2- on:
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 Remove front exhaust system with catalytic converter:
Continued for all models:
Fig. 95: Three Lower Engine And Transmission Connecting Bolts

 Remove the three lower engine and transmission connecting bolts -arrow-.
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Fig. 96: Drive Shafts And Flange Shafts

 Remove the drive shafts -1- from the flange shafts and tie these up.
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NOTE: Do not damage protective coating on drive shafts.
 Support transmission with engine and transmission lifter VAG 1383 A.

 Remove bolts -2- and then bolts -3- on tunnel cross member.
 Remove the two nuts -4- and detach tunnel cross member -2-.
 Lower engine and transmission lifter VAG 1383 A and place to one side.
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 Remove hex socket-head bolt on push rod -arrow B-.
Fig. 99: Identifying Connectors For Vehicle Speed Sensor (VSS) And Back-Up Lights
 Disconnect connector off speedometer sensor -arrow A-.

 Disconnect connector on reversing light switch (multi-function sensor) -arrow B-.
 Disconnect all other electrical connections and ground wires from transmission and from the engine and
transmission securing bolts.
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Fig. 100: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing
 If installed, remove engine speed (RPM) sensor -G28- on left of transmission -arrow- and lay to one side.
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Fig. 101: Removing Starter Bolt
 Remove starter from engine and transmission and secure.
Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
NOTE: Do not disconnect starter cables.
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Fig. 102: Lower Engine And Transmission Connecting Bolts Which Should Not Be Removed
 Remove lower engine and transmission connecting bolts, except for bolts -arrow A- and -arrow B-.
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Fig. 103: Transmission Support 3282 Attachment Plate
 Set the transmission support 3282 for removing the manual 012 with adjustment plate 3282/10 and attach
to transmission lifter VAG 1383 A.
A - Support elements
NOTE:  Support elements -A- are shown in schematic form, arrow -B- points in
direction of travel.
 Adjustment plate 3282/10 only fits in one position.
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Fig. 104: Setting Transmission Jack Under Vehicle

 Place transmission lifter under vehicle. Arrow -B- (See Fig. 103) on adjustment plate points in direction
of travel.
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Fig. 105: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Support On
Transmission
 Align adjustment plate parallel to transmission and lock safety support -arrow- on transmission.
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 Remove engine and transmission connecting bolts (arrows -A- and -B-).
 Push transmission off dowel sleeves and lower carefully with transmission lifter VAG 1383 A just far
enough to access the slave cylinder.
NOTE: When lowering transmission make sure hydraulic line and hose to slave
cylinder is not damaged.
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Fig. 107: Identifying Clutch Slave Cylinder Bracket And Fastener
 Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect lines.
NOTE: Do not depress clutch pedal after removing slave cylinder.
 Lower transmission.
NOTE: When lowering transmission make sure there is sufficient clearance for drive
shafts.
Secure transmission to repair stand with transmission support VW 353 and retaining plate VW 309 to carry out
repairs.
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Fig. 108: Transmission Mount

 If the transmission is exchanged, the transmission mount must be transferred to the exchange
transmission.
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Transmission, transporting
Fig. 109: Transmission Support Jig. 3336

 3336 transmission lifting beam
Transmission lifting beam can be used to transport transmission and when setting up transmission support 3282.
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Fig. 110: Bolting Transmission Support Jig. 3336 To Transmission Housing

 Bolt transmission lifting beam 3336 to clutch housing.
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Fig. 111: Adjust Support Jig On Sliding Piece Using Locking Pin
 Set support arm in slide with locking pin (arrow).
 No. of holes visible = 17
 Lift transmission with workshop crane and transmission lifting beam 3336.
Installing
 Clean input shaft splines and lightly grease with G000 100 grease.
The clutch plate must slide easily back and forth on input shaft.
 Lightly coat contact surface on push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
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 Check whether dowel sleeves for centering engine and transmission in cylinder block have been installed.
 If installed, make sure that intermediate plate is correctly positioned on engine.
 Check clutch release bearing for wear and replace.
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 If plastic ring on release bearing is detached, adhere this back onto bearing ring with adhesive AMV 195
KD1 01.
Three right-angled lugs -arrows- on plastic ring engage in the recesses on bearing ring.
If ridges are deeper than 0.5 mm, replaced release bearing.
 All threaded holes into which self-locking bolts are installed, must be cleaned of locking fluid residue
with a thread tap.
 Replace all self locking nuts.

 Lift transmission until clutch slave cylinder with bracket for hose and line can be installed (arrow).
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 Install lower engine, transmission and starter mounting bolts and install starter.
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 Install tunnel cross member onto transmission mount -4-.

 Install tunnel cross member onto body. First install bolts -3- and then bolts -2-.
 Check shift mechanism adjustment, adjust. Refer to Shift mechanism, adjusting.
 Checking oil level in manual transmission. Refer to Oil level in manual transmission, checking.
 Connect battery.
 After connecting battery, enter anti theft code for radio.
Refer to Operating instructions for radio
NOTE: On re-connecting battery, remember to check and re-activate vehicle equipment

(radio, clock, convenience electronics, etc.).
Refer to
Tightening torques
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Fig. 115: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

Attachment of 4-cylinder engine to transmission
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Item Bolt Nm
1, 3, 4 M12 x 75 65
2 M12 x 90 65
5, 11 M12 x 110 65
7... 10 M10 x 45 45
11 M12 x 130 65
A: Dowel sleeves for centering
Transmission mount with mount to transmission -arrows- 23 Nm
1 - Drive shaft to flange shaft M8 40 Nm

M10 70 Nm
2 - Tunnel cross member to body M10 55 Nm
1)
3 - Tunnel cross member to body 1) 110 Nm
+ 90 °
4 - Tunnel cross member to transmission mounting 23 Nm
1) Always replace bolt with washer
Component Nm
Engine speed (RPM) sensor -G28- 10
Clutch slave cylinder to transmission1) 23
Heat shields over drive shafts to transmission 23
Selector joint to transmission 1) 23
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Tunnel cross member to body 55

Bracket for noise insulation to subframe 10
1) Replace bolt.
OIL LEVEL IN MANUAL TRANSMISSION, CHECKING
Oil level in manual transmission, checking
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Fig. 116: Identifying Triple Square Socket Driver 3357
 3357 socket attachment
Fig. 117: Identifying Torque Wrench V.A.G. 1331

NOTE:  The vehicle must be level when checking transmission oil level. This work
2:14:21 AM Page 83
is best performed over an inspection pit or using a 4 -column lifting

platform.
 The oil filler plug is on the left of the transmission below the speedometer
sensor; it may be concealed by the heat shield for the drive shaft.
 Remove oil drain plug using special tool 3357.
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Fig. 118: Checking Oil Level At Oil Filler Hole
 To check oil level, remove oil filler plug (arrow).

 Check oil level using a shop-built tool, e.g. a piece of angled wire.
 Specification: Oil level 7 mm below bottom edge of oil filler hole
NOTE: In service centers filling to lower edge of filler hole is also permissible.
 Fill with gear oil if necessary: Specification. Refer to Code letters, application, ratios, capacities.

 Install oil filler plug.
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Tightening torque
Component Nm
Oil filler plug 25
TRANSMISSION, DISASSEMBLING AND ASSEMBLING
Transmission, disassembling and assembling
Assembly sequence. Refer to Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion,
selector rods and transmission cover, removing and installing
Transmission overview
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Fig. 120: Transmission, Overview

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1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Reverse gear
 Removing and installing reverse idler. Refer to Reverse idler gear, removing and installing
7 - Transmission housing
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8 - Transmission cover
9 - Input shaft
 Disassembling and assembling. Refer to Input shaft, disassembling and assembling
10 - Drive pinion
 Disassembling and assembling. Refer to Drive pinion, disassembling and assembling
11 - Ball bearing
 Adjusting. Refer to Input shaft, adjusting adjusting input shaft
12 - Differential
 Removing and installing. Refer to Differential, removing and installing

 Disassembling and assembling. Refer to Differential, disassembling and assembling
13 - Tapered roller bearings
 Adjusting. Refer to Drive pinion, adjusting
Assembly overview
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Fig. 121: Transmission, Assembly Overview, I and II
I - Removing and installing input shaft ball bearing and multi-function sensor. Refer to Input shaft ball
bearing and multi-function sensor, removing and installing
II - Removing and installing input shaft, drive pinion, selector rods, transmission cover. Refer to Input
shaft, drive pinion, selector rods and transmission cover, removing and installing
Input shaft ball bearing and multi-function sensor, removing and installing
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Fig. 122: Transmission Housing, Input Shaft Ball Bearing And Multi-Function Sensor, Overview
 With differential and flange shafts

 Removing and installing flange shafts. Refer to Flange shaft oil seal, replacing
 Removing and installing differential. Refer to Differential, removing and installing
 Removing and installing speedometer sensor and drive wheel. Refer to Speedometer sensor and drive
wheel, removing and installing
 Breather installation position. See Installation position of breather
 Self-locking
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 Always replace
3 - Guide sleeve
 With O-ring and seal for input shaft. Refer to Clutch release mechanism, servicing
4 - Dished washer
5 - Circlip
 Determining thickness adjusting. Refer to Input shaft, adjusting
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6 - Ball bearing
 Removing and installing. Refer to Ball bearing for input shaft, multi-function sensor, input shaft,
drive pinion, selector rods and transmission cover, removing and installing
7 - Circlip
2:14:22 AM Page 89
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8 - Input shaft

 Adjusting. Refer to Input shaft, adjusting
 Servicing input shaft bearings. Refer to Input shaft, disassembling and assembling
9 - Bolt
10 - Tab washer
 For multi-function sensor
2:14:22 AM Page 90
11 - Multi-function sensor
12 - Connector for multi-function sensor
13 - Bolt - 10 Nm
14 - Cover for selector shaft
 Removing and installing. Refer to Shift mechanism in transmission, disassembling and assembling
15 - Locking module for 5th gear and reverse gear
 Removing and installing. Refer to Removing and installing locking module for 5th gear and reverse
gear
Installation position of breather
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Fig. 124: Identifying Installed Position Of Breather
The breather must project 21 mm out of housing, after being pressed in.
Input shaft, drive pinion, selector rods and transmission cover, removing and installing
2:14:22 AM Page 91
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Fig. 125: Input Shaft, Drive Pinion, Shift Rods And Transmission Cover, Overview
1 - Selector rod with selector fork for 3rd and 4th gear
 Disassembling and assembling. Refer to Shift mechanism in transmission, disassembling and

assembling
 Replacing mounting bushings. Refer to Shift mechanism in transmission, disassembling and
assembling
2 - Input shaft

 Servicing input shaft bearings. Refer to Input shaft, adjusting
2:14:22 AM Page 92
3 - Left stop bolt - 40 Nm
4 - Washer
5 - Relay shaft
 Installation position. Refer to Shift mechanism in transmission, disassembling and assembling
6 - Washer
7 - Right stop bolt - 40 Nm
8 - Selector shaft

 Replace selector shaft sealing ring. Refer to Shift mechanism in transmission, disassembling and
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assembling
9 - Detent segment
 With collar to secure the detent segment spring
11 - Selector rod with selector fork for 1st/2nd/5th and reverse gear

assembling
 Removing and installing ball sleeves. Refer to Removing and installing ball sleeve
12 - Drive pinion

 Servicing drive pinion bearings. Refer to Drive pinion, disassembling and assembling
 Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces
 Removing and installing oil collector. Refer to Removing and installing oil collector
2:14:22 AM Page 93
 Match components according to transmission code letters
Removing and installing oil collector
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Fig. 126: Identifying Oil Collector Tray
Removing
 Turn the oil collector arrow- and then pull out.
Installing
 Push oil collector into transmission cover until it snaps in place.
 Installation position: Oil collector faces upward in transmission cover
Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion, selector rods and transmission cover,
removing and installing
2:14:22 AM Page 94
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Fig. 127: Identifying Special Tools - Disassembly And Assembly
 VW 309 Holding plate

 VW 353 Transmission support
 3235 Press Device
 3357 Triple square socket driver
 VAG 1582 Tapered roller bearing puller

 VAG 1582/2 Gripping piece
2:14:22 AM Page 95
Fig. 128: Identifying Drip Tray V.A.G 1306

 VAG 1306 Drip tray
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 Sealant AMV 188 001 02
NOTE:  It is not necessary to remove the differential to remove the above-

mentioned components.
 Removal is only necessary when adjustments have to be carried out
adjustment overview:
Removing
 Place drip tray VAG 1306 underneath the transmission.

 Drain gear oil, using socket attachment 3357.
2:14:22 AM Page 96
Fig. 130: Securing Transmission To Assembly Stand

 Secure transmission to repair stand.
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Fig. 131: Clutch Release Lever Components
 Detach clutch release lever -A- with release bearing.
NOTE: Cover input shaft splines with a shrink-fit hose to protect oil seal, before pulling
off guide sleeve.
 Remove guide sleeve -B-.

 Remove dished washer -C-.
 In front of input shaft ball bearing remove circlip -D-.
 Note the thickness of the circlip, if the ball bearing, input shaft or transmission housing is not being
replaced.
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Fig. 132: Pulling Input Shaft Ball Bearing Out Of Transmission Housing
 Pull the input shaft ball bearing out of the transmission housing.
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Fig. 133: Location Of Rear Circlip For Input Shaft Ball Bearing
 Remove the circlip (arrow) behind the input shaft ball bearing.
replaced.
2:14:22 AM Page 98
Fig. 134: Transmission Cover Installed On Transmission Housing

 Remove transmission cover -A- from transmission housing -B-.
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Fig. 135: Location Of Multi-Function Sensor
 Remove bolts (arrows) and pull out the multi-function sensor.
Fig. 136: Identifying Threaded Bolts At Both Ends Of Relay Shaft

 Remove relay shaft bolts (arrows).
2:14:22 AM Page 99
Fig. 137: Identifying Shift Detent Fastener

 Remove detent segment (arrow) and swivel it out.
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Fig. 138: Identifying Input Shaft, Drive Pinion, Relay Shaft, Shift Rods With Selector Shaft And Selector
Forks
 The input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector
forks -E- must be carefully pulled out together.
Installing
NOTE: If input shaft ball bearing, input shaft or the transmission housing are replaced,
it is necessary to re-determine the thickness of circlips for input shaft. Refer to
Input shaft, adjusting, adjusting input shaft.
2:14:22 AM Page 100

Fig. 139: Swing Transmission Housing Into Position Shown

 For easier installation of following components, swing transmission housing into the position shown.
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Fig. 140: Assemble Input Shaft, Drive Pinion, Relay Shaft, Selector Rods With Shift Rod And Selector
Forks
 Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and
selector forks -E-.
 Install these components together into transmission housing.
NOTE: Relay shaft -C- and selector shaft can also be installed later. Refer to Fig. 143.
2:14:22 AM Page 101

Fig. 141: Identifying Installed Position Of Complete Selector Mechanism In Transmission

Location of shift mechanism in transmission
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1 - Selector fork for 5th gear and reverse gear
2 - Selector fork for 3rd gear and 4th gear
3 - Selector fork for 1st gear and 2nd gear
4 - Relay shaft
5 - Detent mechanism
6 - Selector shaft
NOTE: Shown in illustration with input shaft and drive pinion removed.
Fig. 142: Move Transmission To Engage 3rd Gear

 Turn transmission housing and engage 3rd gear (direction of arrow).
2:14:22 AM Page 102

Fig. 143: Installing Relay Shaft And Shift Rod

 Install relay shaft -A-.
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 Insert selector shaft -B- sideways into hole in transmission housing and assemble into mounting eye.
 Turn the selector shaft in direction of arrow.

 Insert the detent segment and tighten bolt (arrow).
2:14:22 AM Page 103


 Install relay shaft bolts (arrow).
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 Replace O-ring for multi-function sensor.

 Carefully insert multi-function sensor and tighten (arrow).
2:14:22 AM Page 104

Check that dowel sleeves for transmission cover -A- are installed in transmission housing -B-.
 Apply thin coat of sealant AMV 188 001 02 to sealing surfaces.

 Install transmission cover onto transmission housing.
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 Install rear input shaft ball bearing circlip (arrow).

 Slide the ball bearing onto input shaft.
 Installation position: Closed side of ball cage faces toward transmission housing
Fig. 149: Pressing In Ball Bearing

 Press in ball bearing:
 Slide thrust pad -A- on press-in tool onto input shaft.

 Position press-in tool behind splines for clutch plate.
 Install bolts -B- until they make contact.
2:14:22 AM Page 105

 The bolts bear against the indentations in thrust pad -A-.
 Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).
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 Install front circlip -D- for the input shaft ball bearing.
 Install dished washer -C-.
 Installation position: Convex side toward guide sleeve -B-
NOTE: Before installing guide sleeve, cover input shaft splines with a shrink-fit hose to
protect oil seal.

 Install guide sleeve -B- for release bearing.

 Install clutch release lever -A- and release bearing.
SHIFT MECHANISM IN TRANSMISSION, DISASSEMBLING AND ASSEMBLING
2:14:22 AM Page 106

Shift mechanism in transmission, disassembling and assembling
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Fig. 152: Identifying Special Tools - Shift Mechanism On Transmission Side, Disassembling And
Assembling
 VW 295 Drift
 VW 295 A adapter
 VW 401 Thrust plate
 VW 420 Tube
 VW 423 Tube
 VW 472/2 Spacer sleeve
2:14:22 AM Page 107

Fig. 153: Slide Hammer-Multi-Purpose Tool Set VW 771

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 VW 771 Multi-purpose tool
Fig. 154: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support
 1 - Kukko 21/4 Internal puller
NOTE: Installation position of complete shift mechanism in transmission. See

Installation position of complete shift mechanism in transmission
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Fig. 155: Shift Mechanism In Transmission, Overview
gear
3 - O-ring
 Always replace
2:14:22 AM Page 109

5 - Washer
6 - Relay shaft
7 - Washer
9 - Detent segment
11 - Spring pin
12 - 5th and reverse gear selector fork
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 Installation position. Refer to Installation position of 5th and reverse gear selector fork and follower
for selector rod
13 - Selector rods for 1st/2nd and 5th/reverse gear
14 - Ball sleeve
 Removing and installing. Refer to Removing and installing ball sleeve
15 - Selector fork, 1st and 2nd gear
16 - Relay lever
for selector rod
17 - Mounting bushing for 3rd and 4th gear
 Pulling out. Refer to Pulling out mounting bushing for 3rd and 4th gear selector rod
 Driving in. Refer to Driving mounting bushing for 3rd and 4th gear selector rod home
18 - Ball sleeve
 Pry off the selector rod with a screwdriver

 Press on the selector rod
19 - Selector rod for 3rd and 4th gear
20 - Selector fork, 3rd and 4th gear
2:14:22 AM Page 110

21 - Spring pin
22 - Cover plate
 For selector shaft
24 - Selector shaft
25 - Sealing ring
 Pry out with screwdriver

 Insert using tube VW 420
 Installation position. See Installation position of oil seal.
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Installation position of 5th and reverse gear selector fork and follower for selector rod
Fig. 156: Identifying Installed Position For 5th/Reverse Gear Shift Fork And Coupling Plate For Shift
Rod
 Dimension a = 55 mm
Removing and installing ball sleeve
2:14:22 AM Page 111

Fig. 157: Removing/Installing Ball Sleeve

Pulling out mounting bushing for 3rd and 4th gear selector rod
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Fig. 158: Removing Bushing For 3rd And 4th Gear Shift Rod
A - Internal puller 22... 28 mm, e.g. Kukko 21/4, in conjunction with multi-purpose tool VW 771
Driving mounting bushing for 3rd and 4th gear selector rod home
2:14:22 AM Page 112

Fig. 159: Driving In Bushing For 3rd And 4th Gear Shift Rod
Installation position of oil seal
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Fig. 160: Identifying Installed Position Of Sealing Washer
 Fill space between sealing and dust lips with multi-purpose grease.
 Lightly oil outer circumference of seal.
 Insert oil seal using tube VW 420

2:14:22 AM Page 113

4 - Relay shaft
6 - Selector shaft
Removing and installing locking module for 5th gear and reverse gear
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 Remove heat shield - arrow 2- above right-hand drive shaft.

 Detach heat shield -arrow 1- above right-hand drive shaft and pivot downward.
Fig. 163: Identifying Gear Lock

 Remove locking module -arrow-.
Assembling locking module:
2:14:22 AM Page 114

Fig. 164: Assembling Gear Lock

 Insert spring -1- into housing -2-, while exerting light pressure, turn spring to the left until it locates in the
base of the housing.
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 Insert bushing -3- into the spring so that the bent end of the spring locates in the designated groove.
 Push bushing -3- against spring and turn approx. one turn to left, until the lug on the bushing aligns with
the groove in the housing -2-.
 Press lug on bushing -3- onto stop in the groove in the housing -2-.
 Turn bushing -3- clockwise and release; bushing -3- springs to installation position.

Installation position of bushing:
The lug (arrow -A-) on the bushing must always be opposite the groove in the housing (arrow -B-).
Check installation position:
 Turn bushing counterclockwise and release.
2:14:22 AM Page 115

 The bushing must spring back; the lug must lie against the stop -direction of arrow A-
Fig. 166: Installed Position Of Complete Gear Lock In Transmission

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Installation position of complete locking module in transmission:
The recess (arrow -A-) faces bolt (arrow-B-)
35 MANUAL TRANSMISSION - GEARS, SHAFTS

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
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Fig. 167: Identifying Special Tools - Input Shaft, Disassembling And Assembling
 VW 295 Needle bearing drift

 VW 295 A Needle bearing drift
 VW 407 Punch
 VW 408 A Punch
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 VW 415 A Tube
 VW 416 B Tube
 VW 447 i Thrust pad
 VW 771 Slide hammer - complete set
 30-100 Press tube

 40-105 Thrust piece
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 VW 222 A Mandrel
 30-24 Mandrel
 40-202 Press tool
 1 - Kukko 21//4 Internal puller
 3 - Kukko 17/2 Separating tool
NOTE:
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Fig. 170: Input Shaft, Overview
 When installing new gears or the input shaft consult technical data. Refer to Code letters, application,
ratios, capacities.
 If -items 2, 4 or 6 under Input shaft, disassembling and assembling are replaced the position of the ball
bearing will be affected. The input shaft should be re-adjusted. Refer to Input shaft, adjusting.
1 - Circlip
 Mark
 Installation position Installation position of circlips - item 1
 Determining thickness. Refer to Input shaft, adjusting adjusting input shaft
2 - Ball bearing
2:14:22 AM Page 120

3 - Circlip
 Mark
 Installation position Installation position of circlips item 2
 Determining thickness. Refer to Input shaft, adjusting
5 - Needle bearing
 Secured with bolt. See Remove securing bolt -arrow- for needle bearing
 Driving out. See Driving out needle bearing
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 Installation position. See Installation position of needle bearing
 Pressing in. See Pressing in needle bearing
 Locking. See Screwing in securing bolt -arrow-
6 - Input shaft
 With oil feed sleeve

 Knocking in oil feed sleeve. See Driving oil feed sleeve into input shaft
7 - Needle bearing for 3rd gear
 Mark
8 - 3rd speed sliding gear
9 - Spring
 Insert in 3rd speed sliding gear. See Inserting spring in sliding gear
 Allocation of spring to sliding gear
10 - Synchro-ring for 3rd gear
 Check for wear. See Checking synchro-ring for wear
11 - Circlip
 Mark
2:14:23 AM Page 121

12 - Synchro-hub for 3rd and 4th gear
 High collar faces 3rd gear

 Pressing off. See Pressing off synchro-hub for 3rd and 4th gear
 Pressing on. See Pressing on synchro-hub for 3rd and 4th gear
13 - Circlip
 Mark
 Installation position. See Installation position of circlips item 4
 If synchro-hub is replaced re-determine thickness. See Determining thickness of circlip
14 - Locking collar for 3rd and 4th gear
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 Installation position. See Installation position of locking collar
15 - Synchro-ring for 4th gear
16 - Spring
 Insert in 4th speed sliding gear. See Inserting spring in sliding gear
17 - 4th gear sliding gear
18 - Needle bearing for 4th gear
 Mark
19 - 5th gear wheel
 Pressing off. See Pressing off 5th gear wheel

 Pressing on. See Pressing on 5th gear wheel
20 - Circlip
 Mark
 If the 5th gear wheel is replaced re-determine thickness. See Determining thickness of circlip
2:14:23 AM Page 122

21 - Roller sleeve
 Replace
 Will be damaged during removal
 Pulling out. See Pulling out roller sleeve
 Installation position. See Installation position of roller sleeve
 Tapping in. See Driving in roller sleeve
22 - Sleeve
 Made of plastic
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Remove securing bolt -arrow- for needle bearing
Fig. 171: Location Of Securing Bolt

 Remove securing bolt -arrow-.
NOTE: Bolt is not installed on all versions.
Driving out needle bearing
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Fig. 172: Driving Out Needle Bearing

Installation position of needle bearing
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Fig. 173: Installation Position Of Needle Bearing
Distance -a- from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm
NOTE: Measure distance from top edge of straight-edge and subtract the width of the
straight-edge from the measured distance.
Pressing in needle bearing
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Fig. 174: Pressing In Needle Bearing

Screwing in securing bolt -arrow-
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 Tighten to 25 Nm
Driving oil feed sleeve into input shaft
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Fig. 176: Driving In Oiling Sleeve Into Input Shaft

Item Oil feed sleeve dia. Fitting tool
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A 14 mm VW 222 A
B 16 mm 30-24
Flanged edge on oil feed sleeve faces toward fitting tool
 Insertion depth:
3.5 mm below top edge
Pulling out roller sleeve
Fig. 177: Removing Roller Sleeve

A - Internal extractor, e. g. Kukko 21/4, 22... 28 mm
Before installing internal extractor, the plastic sleeve inside the roller sleeve must be destroyed.
2:14:23 AM Page 126

Installation position of roller sleeve
Fig. 178: Installed Position Of Roller Sleeve

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Driving in roller sleeve
Fig. 179: Driving In Roller Sleeve

Pressing off 5th gear wheel
2:14:23 AM Page 127

Fig. 180: Pressing Off 5th Gear

 Remove circlip before pressing off.
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A - Separating device 22... 115 mm, e.g. Kukko 17/2
Pressing off synchro-hub for 3rd and 4th gear
Fig. 181: Pressing Off Synchro-Hub For 3rd And 4th Gear

 Press 3rd gear synchro ring (arrow) toward 3rd gear wheel, then install separating device -A-.
Inserting spring in sliding gear
2:14:23 AM Page 128

Fig. 182: Inserting Spring Into Gear

The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.
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Checking synchro-ring for wear
Fig. 183: Checking Synchronizer For Wear

 Press synchro-ring into locking collar and measure gap -a- with a feeler gauge at positions -A-, -B- and -
C-.
 Add the measured values and divide by 3.
The average value must not be less than 0.5 mm.
Installation position of circlips
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Fig. 184: Identifying Installed Positions Of Circlips
 Circlips -1- and -2- secure the input shaft ball bearing Adjusting input shaft: Refer to Input shaft,
adjusting.
 Circlip -3- secures the 3rd and 4th gear synchro-hub.
Thickness 2.00 mm. Identification: Brown color.
Determining thickness table on. Refer to Available circlips for 3rd and 4th gear synchro-hubs
 Circlip -5- secures the 5th gear wheel.
Determining thickness table on. Refer to Available circlips for 5th gear wheel.
Determining thickness of circlip
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Fig. 185: Determining Circlip Fit
 Determine thickest circlip that will just fit and install it.
 Determine circlip as accurately as possible from table. Part numbers
Available circlips for 3rd and 4th gear synchro-hubs

Circlip thickness (mm)
1.90 1.96 2.02
1.93 1.99 2.05
Available circlips for 5th gear wheel

1.90 1.96 2.02
1.93 1.99
Pressing on synchro-hub for 3rd and 4th gear
2:14:23 AM Page 131

Fig. 186: Pressing On Synchronizer Hub For 3rd And 4th Gears
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High inside collar faces 3rd gear
Installation position of locking collar
Fig. 187: Identifying Installed Position Of Operating Sleeve Up To Transmission Manufacture Date 22 06
3
Different types of locking collar are installed: illustration -A-, arrow 1- with chamfered edge, or illustration -B-,
arrow 3- with large shoulder.
2:14:23 AM Page 132

Chamfered edge -arrow 1- faces 4th gear
Small shoulder -arrow 2- faces 3rd gear
Large shoulder -arrow 3- faces 4th gear
Pressing on 5th gear wheel
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Fig. 188: Pressing On 5th Gear
WARNING: Wear protective gloves.
 Heat 5th gear wheel to approx. 100 ° C before pressing on.
High collar faces reverse gear
INPUT SHAFT, ADJUSTING
Input shaft, adjusting
(determining circlips for input shaft)
2:14:23 AM Page 133

Fig. 189: Press Tube 30-100Identifying Special Tools - Oil Pump/Front Sealing Flange, Drive Chain And
Chain Sprocket For Oil Pump, Removing And Installing
30-100 Press tube
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
Fig. 190: Spacer Gauge 3167

 3167 Spacer gauge

 Depth gauge
It is necessary to readjust input shaft when the:
 Transmission housing
 Input shaft
or
 Ball bearing
are replaced.
2:14:23 AM Page 134

Fig. 191: Placing Transmission Housing Over Input Shaft Onto Spacer Gauge
 Clamp input shaft in vice using soft jaws -A-.
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 Place distance gauge 3167 onto 3rd gear sliding gear.
 Place transmission housing over input shaft onto the distance gauge.
Fig. 192: Determining Circlip Thickness, Measuring Value "a"

 Place depth gauge onto transmission housing and measure to the lower circlip groove in the input shaft.
 Measurement in following example: -a- = 28.50 mm
2:14:23 AM Page 135

Fig. 193: Determining Circlip Thickness, Measuring Value "b"

 Place depth gauge onto transmission housing and measure to seat surface for ball bearing.
cardiagn.com
 Measurement in following example: -b- = 26.80 mm
Determining circlip x behind the input shaft ball bearing.
Formula:
"x" = Dimension "a" - dimension "b"
Example:
Dimension "a" 28.50 mm
- Dimension "b" 26.80 mm
= Dimension "x" (thickness of 1.70 mm
circlip)
 Determine circlip from table. Part numbers
Available circlips
Dimension "x" Thickness (mm)

1.48... 1.56 1.54
1.57... 1.65 1.63
1.66... 1.74 1.72
1.75... 1.83 1.81
1.84... 1.92 1.90
1.93... 2.01 1.99
2.02... 2.10 2.08
2.11... 2.20 2.17
2.21... 2.27 2.25
2:14:23 AM Page 136

2.28... 2.35 2.33
Determining the circlip in front of the input shaft ball bearing
 Knock rear circlip (as calculated) and ball bearing onto input shaft with fitting sleeve 30-100.
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Fig. 194: Input Shaft And Thickest Circlip Which Can Still Just Be Installed
 Determine the thickest circlip which will still fit.

Available circlips

1.45 1.72 1.99
1.54 1.81 2.08
1.63 1.90 2.17
DRIVE PINION, DISASSEMBLING AND ASSEMBLING
Drive pinion, disassembling and assembling
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Fig. 195: Identifying Special Tools - Output Shaft

 VW 407 Thrust tool
 VW 408 A Pressure tool

 VW 415 A Tube
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Fig. 196: Identifying Special Tools - Transmission, Disassembling And Assembling
 Crankshaft seal installing tool VW 204 B

 VW 421 Tube
 VW 455 Pressing-on sleeve
 VW 519 Tube

 2010 Tube
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 3005 Thrust plate

 3118 Thrust piece
 3128 Puller
 3301 Assembly equipment

NOTE:
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Fig. 198: Exploded View Drive Pinion Up To Transmission Manufacture Date 22
06 3
 When installing new gears or the final drive set consult technical data. Refer to Code letters,
application, ratios, capacities.
 Adjustments are required when replacing components marked 1).
1 - Transmission housing 1)
2 - Shim "S3"
3 - Outer race for large tapered roller bearing 1)
 Pulling out. See Pulling out outer race for large tapered roller bearing
 Pressing in. See Pressing in outer race for large tapered roller bearing
2:14:23 AM Page 141

4 - Drive pinion1)
 Is mated with ring gear, replace together as a set

 Adjusting ring gear and drive pinion. Refer to Drive pinion and ring gear, adjusting
5 - Inner race for large tapered roller bearing 1)
 Always replace
 Pressing off. See Pressing off inner race for large tapered roller bearing
 Pressing on. See Pressing on inner race for large tapered roller bearing
6 - Circlip
 Mark
cardiagn.com
 Re-determine thickness if tapered roller bearing is replaced. See Determining thickness of circlip
8 - 1st gear sliding gear
9 - Spring
 Insert in 1st gear sliding gear. See Inserting spring in sliding gear
10 - Synchro-ring for 1st gear
11 - Synchro-hub for 1st and 2nd gear
 Pressing off. See Pressing off synchro-hub for 1st and 2nd gear
 Pressing on. See Pressing on synchro-hub for 1st and 2nd gear
12 - Circlip
 Mark
 Re-determine if the synchro-hub is replaced. See Determining thickness of circlip
13 - Needle bearing for 2nd gear
2:14:23 AM Page 142

14 - Locking collar, 1st and 2nd gear
 Installation position. See Installation position of locking collar for 1st and 2nd gear
15 - Synchro-ring for 2nd gear
16 - Spring
 Insert in 2nd gear sliding gear. See Inserting spring in sliding gear
17 - 2nd gear sliding gear
18 - Circlip
cardiagn.com
 Mark
19 - 3rd gear wheel
 Pressing off. See Pressing off 3rd gear wheel

 Shoulder points to 4th gear
 Pressing on. See Pressing on 3rd gear wheel
20 - Circlip
 Mark
 Re-determine thickness If the 3rd gear wheel is replaced. See Determining thickness of circlip
21 - 4th gear wheel

 Shoulder points to 3rd gear
22 - Circlip
 Mark
 Re-determine thickness if the 4th gear wheel is replaced. See Determining thickness of circlip
2:14:23 AM Page 143

23 - Needle bearing
25 - Spring
 Insert in 5th gear sliding gear. See Inserting spring in sliding gear
27 - Circlip
 Mark
cardiagn.com
28 - 5th gear and reverse gear synchro-hub
 Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
 Pressing on. See Pressing on 5th gear and reverse gear synchro-hub
29 - Circlip
 Mark
 If the synchro-hub is replaced re-determine. See Determining thickness of circlip
30 - Needle bearing
 For reverse gear
31 - Locking collar for 5th and reverse gear
 Installation position. See Installation position of locking collar for 5th and reverse gear
32 - Reverse gear synchro-ring
33 - Spring
 Insert in reverse gear sliding gear. See Inserting spring in sliding gear
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34 - Reverse gear sliding gear
35 - Inner race for small tapered roller bearing 1)
 Pressing off. See Pressing off inner race for small tapered roller bearing
 Pressing on. See Pressing on inner race for small tapered roller bearing
36 - Socket
 To secure small tapered roller bearing outer race

 Pulling out. See Pulling out securing bushing for small tapered roller bearing outer race
 Need not be fitted after the small tapered roller bearing has been replaced.
37 - Outer race for small tapered roller bearing 1)
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 Pulling out. See Pulling out outer race for small tapered roller bearing
 Pressing in. See Pressing in outer race for small tapered roller bearing
38 - Shim "S4"
39 - Pressure plate
40 - Rubber disc
 Compensates length variations

 To remove, insert self-tapping screw center and pull out washer on self-tapping screw.
 Use components according to the transmission code letters. Refer to Code letters, application, ratios,
capacities.
Pulling out securing bushing for small tapered roller bearing outer race
2:14:23 AM Page 145

Fig. 199: Pulling Off Securing Bushing For Small Tapered Roller Bearing Outer Race
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Pulling out outer race for small tapered roller bearing
Fig. 200: Pulling Off Outer Race Of Small Tapered Roller Bearing
 Screw special tool VW 771/40 into pressure plate

 Install multi-purpose tool VW 771 and pull outer race out via pressure plate.
Pressing in outer race for small tapered roller bearing
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Fig. 201: Pressing In Outer Race For Small Tapered Roller Bearing
Pulling out outer race for large tapered roller bearing
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Fig. 202: Pulling Out Double Tapered Roller Bearing Outer Race
 Remove differential. Refer to Differential, removing and installing.

 Place pressure piece of puller 3128 below the outer race.
 Install threaded spindle and pressure bearing of assembly device 3301 with pressure plate VW 401 onto
When tightening bolt the outer race will be pulled out of housing.
Pressing in outer race for large tapered roller bearing
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Fig. 203: Pressing In Double Tapered Roller Bearing Outer Race

The smaller diameter of special tool VW 204 b faces outer race.
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Pressing off inner race for small tapered roller bearing
Fig. 204: Pressing Off Tapered Roller Bearing Inner Race

 Press off inner race with reverse gear sliding gear.
Pressing off 5th gear and reverse gear synchro-hub
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Fig. 205: Pressing Off Synchronizer Hub For 5th And Reverse Gear
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 Press off synchro-hub with 5th gear sliding gear.

Pressing off 3rd gear wheel
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Fig. 207: Pressing Off 3rd Gear

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 Pressing off 3rd gear wheel with 2nd gear sliding gear.
Pressing off synchro-hub for 1st and 2nd gear
Fig. 208: Pressing Off Synchronizer Hub For 1st And 2nd Gears

 Press off synchro-hub with 1st gear sliding gear.
Pressing off inner race for large tapered roller bearing
2:14:23 AM Page 150

Fig. 209: Pressing Off Double Tapered Roller Bearing Inner Race
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The outer race -A- must be installed to press off the inner race.
Pressing on inner race for large tapered roller bearing
Fig. 210: Pressing On Inner Race For Large Tapered Roller Bearing
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 Determine thickest circlip which will still fit and install it.
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The circlips for synchro-hubs and individual gear wheels should also be determined as shown for tapered roller
bearing.
Available circlips and part numbers
Fig. 212: Identifying Installed Position Of Circlips

The circlips for synchro-hubs, needle roller bearings and individual gear wheels should also be determined.
Refer to Determining thickness of circlip.
2:14:23 AM Page 152

 Circlip -1- secures the inner race for tapered roller bearing.

2.00 2.06 2.12
2.03 2.09 2.15
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 Circlip -2- secures the 1st and 2nd gear synchro-hub.
Distinguishing features. Color - blue

1.90 1.96 2.02
1.93 1.99
 Circlip -3- secures the needle bearing for 2nd gear sliding gear.

2.50
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 Circlip -4- secures the 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02

1.86 1.94
1.90 1.98
 Circlip -6- secures the needle bearing for 5th gear sliding gear.
Distinguishing features. color - brown

2.00
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 Circlip -7- secures the synchro-hub for 5th gear and reverse gear.
Distinguishing features. color - blue

1.90 1.96 2.02
1.93 1.99 2.05
 Determine circlips according to table: Part numbers

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C-.
 Add measured values and divide by 3.
Calculated value must not be less than 0.5 mm.
Pressing on synchro-hub for 1st and 2nd gear
Fig. 218: Pressing On Synchronizer Hub For 1st And 2nd Gears
High inside collar faces 2nd gear
Installation position of locking collar for 1st and 2nd gear
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Fig. 219: Identifying Installed Position Of Operating Sleeve For 1st And 2nd Gear
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Chamfered edge -arrow 1- faces 2nd gear
Shoulder -arrow 2- faces 1st gear
Pressing on 3rd gear wheel
Fig. 220: Pressing On 3rd Gear

Groove on gear wheel faces 4th gear
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Pressing on 5th gear and reverse gear synchro-hub
Fig. 222: Pressing On Synchronizer Hub For 5th And Reverse Gear
High inside collar faces 5th gear
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NOTE: Large inner diameter in special tool 2010 faces synchro-hub.
Installation position of locking collar for 5th and reverse gear
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3
 Make sure locking collar is correct version for reverse gear wheel. See Selecting correct locking collar
for reverse gear wheel
Chamfered edge -arrow 1- faces reverse gear
Small shoulder -arrow 2- faces 5th gear
Large shoulder -arrow 3- faces reverse gear
Pressing on inner race for small tapered roller bearing
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Fig. 224: Pressing On Tapered Roller Bearing Inner Race
Selecting correct locking collar for reverse gear wheel
Fig. 225: Allocation Of Operating Sleeve To Reverse Idler Gear

A Reverse gear wheel with Both types of locking collar can be

chamfered edge installed (with chamfered edge or
large shoulder).
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B Reverse gear wheel without Install only locking collar with

chamfered edge. large shoulder, do not use locking
collar with chamfered edge.
REVERSE IDLER GEAR, REMOVING AND INSTALLING
Reverse idler gear, removing and installing
Fig. 226: Reverse Idler Gear, Overview

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1 - Circlip
2 - Support plate
3 - Reverse idler gear
2:14:24 AM Page 161

 Different versions, assignment. See Selecting correct locking collar for reverse gear wheel
4 - Needle bearing
5 - Thrust washer
 With reverse idler gear shaft (arrow)

 It is not necessary to remove the reverse idler gear shaft to remove the reverse idler gear
 The reverse idler gear shaft is not available as a replacement part
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 To secure reverse idler gear shaft
39 FINAL DRIVE, DIFFERENTIAL

FLANGE SHAFT OIL SEAL, REPLACING
2:14:24 AM Page 162

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Fig. 227: Identifying Special Tools
(Transmission installed)
 Observe general repair instructions. Refer to General repair instructions.

 VW 681 Extractor lever
 2062 Driver
 T10037 Puller

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NOTE:  Removal procedure is identical for left and right seals.

 Exhaust system does not have to be removed.
Removing
 Turn steering to full left lock.

 Remove cover plates over right drive shaft (arrows 1 and 2).
 If installed, remove cover plate over left drive shaft.
 Unbolt drive shaft from flange on transmission:
 Tie up drive shaft as high as possible. Do not damage paint on drive shaft.
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When replacing left oil seal:
Remove left flange shaft.
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Fig. 230: Removing Drive Flange (Left Side)
 Remove flange shaft; by screwing puller T10037 to differential cover (arrow).
When replacing right oil seal:
Fig. 231: Removing Drive Flange (Right Side)

 Remove flange shaft, by screwing puller T10037 to transmission housing (arrow).
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Fig. 232: Removing And Installing Securing Ring
 Always replace flange shaft circlip.
 Clamp flange shaft in vice using soft jaws. Press out old circlip from groove in flange shaft use new
circlip -A-.
 Pull out flange shaft oil seal with VW 681.
Fig. 233: Flange Shaft Design

Assembling flange shaft with polygon bearing
1 - Flange shaft
2 - Needle bearing (polygon bearing)
2:14:24 AM Page 166

3 - Spacer ring
4 - Circlip
5 - Spacer ring - installed on shafts with 30 mm spline diameter
NOTE:  Rough running of the polygon bearings with flange shaft removed, does
not indicate bearings are defective. An acoustic test can only be
performed when installed.
 Inspect for signs of damage to polygon bearings (such as cracking in
outer race).
 The polygon bearings can only be replaced together with flange shaft.
 A spacer ring -5- is installed between the polygon bearing and large
differential bevel gear on flange shafts with 30 mm spline diameter.
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Installing
NOTE:  If used flange shaft is used, insert to a depth of 6.5 mm.

 Oil seal can also be driven in using drift 2062.
Fig. 234: Installing Right-Hand Drive Flange Seal

 Keep seal straight when installing. Drive in new oil seal for right flange shaft to a depth of 5.5 mm below
outer surface of housing.
 Fill space between sealing lip and dust lip with sealing grease G052 128 A1.
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Fig. 235: Installing Left-Hand Drive Flange Seal

 Keep seal straight when installing. Drive in new oil seal for left flange shaft to a depth of 5.5 mm below
surface of cover.
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 Drive in flange shaft using mandrel VW 295.
 Bolt drive shaft to flange shaft.
 Install splash plates for drive shaft.
 Check oil level in manual transmission. Refer to Oil level in manual transmission, checking.
Tightening torques
Component Nm
Drive shaft to flange shaft M8 40
M10 70
Drive shaft heat shields 23
SPEEDOMETER SENSOR AND DRIVE WHEEL, REMOVING AND INSTALLING
Speedometer sensor and drive wheel, removing and installing
 Transmisison installed
Speedometer Vehicle Speed Sensor (VSS) -G22-, removing and installing
Removing
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Fig. 236: Identifying Speedometer Vehicle Speed Sensor (VSS) and O-ring
 Pull connector off sensor -A-.
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 Press retaining clip down, turn sensor sideways and pull out upward.
Installing
 Replace O-ring -B- during installation.

 Insert sensor and click into place.
 Handle sensor carefully. If damaged it is possible that speedometer will not be accurate.
Speedometer drive wheel, removing and installing
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 VW 295 Mandrel
 VW 681 Release lever
 2062 Drift
 T10037 Puller

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Removing

 Unbolt drive shaft from flange shaft.
 Place drip tray underneath.


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 Remove speedometer sensor. Refer to Speedometer Vehicle Speed Sensor (VSS) -G22-, removing and
installing.
 Remove speedometer drive wheel:
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Fig. 240: Press Drive Gear Retaining Clips In Direction Of Arrows Using Screwdriver
 With a screwdriver press retaining clips in direction of arrows.

 Remove drive wheel by prying out, alternating between sides.
Installing
NOTE: Install the drive wheel carefully onto the differential, make sure that it is kept
straight. Do not use excessive force - the drive wheel can break.
Installation position:
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Fig. 241: Identifying Installed Position Of Drive Gear, Retaining Clip And Seal
The drive peg of the drive wheel -A- faces seal -B- located in the groove of the differential.
The retaining clips (arrows) located in the annular groove in the differential.
 Always replace oil seal -B- and circlip -C-. Refer to Flange shaft oil seal, replacing.
 Check oil level and fill oil in transmission. Refer to Oil level in manual transmission, checking.
Tightening torques
Component Nm
M10 70
DIFFERENTIAL, REMOVING AND INSTALLING
Differential, removing and installing
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Fig. 242: Identifying Special Tools - Differential, Removing And Installing

 3257 Socket attachment SW 27
 V.A.G 1331 Torque wrench
NOTE:  Removal and installation is possible with transmission installed.

 The differential can be removed and installed without removing selector
mechanism, input shaft, drive pinion and transmission cover. Removal of
the components above is necessary to adjust the differential.
 Inspect polygon bearings for visible damage.
2:14:24 AM Page 174

 Rough running of the polygon bearings with flange shaft removed, does not indicate that bearings are
defective. An acoustic test can only be performed installed.
 A spacer ring is installed between the polygon bearing and the large differential bevel gear on flange
shafts with 30 mm spline diameter. See Assembling flange shaft, -item 5-.
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Fig. 243: Differential, Removal And Installation, Overview
2 - Sealing ring
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 Replacing. Refer to Flange shaft oil seal, replacing
3 - Circlip
 Replace
 Removing and installing. See Removing and installing circlip
4 - Spacer ring
 Is only inserted on flange shafts with spline diameter of 30 mm.

 Removing. See Removing spacer ring
 Installing. See Installing spacer ring
5 - Flange shaft
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 Assembling flange shaft, Assembling flange shaft
6 - Differential with ring gear 1)
 Can be removed without removing gear cluster

7 - Cover for final drive 1)
9 - Speedometer drive wheel
 Removing and installing. Refer to Speedometer drive wheel, removing and installing
 Carefully install the drive wheel onto the differential, make sure that it is kept straight. The drive wheel
can break using excessive force.
Removing and installing circlip
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circlip -A-.
Removing spacer ring
Fig. 245: Removing Spacer Ring

A - Internal puller 18.5... 23.5 mm, e.g. Kukko 21/3
 Pull out spacer ring using multi-purpose tool VW 771.
Installing spacer ring
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Fig. 246: Installing Spacer Ring

 Drive new spacer ring home, take care not to bend ring.
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Assembling flange shaft
Fig. 247: Flange Shaft Assembly, Overview

1 - Flange shaft
3 - Spacer ring
4 - Spacer ring - additionally installed on shafts with 30 mm spline diameter
5 - Circlip
NOTE: The needle bearings (polygon bearings) do not turn easily when the flange shaft
is removed. This does not indicate a bearing is faulty.
2:14:24 AM Page 178

DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
Differential, disassembling and assembling
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Fig. 248: Identifying Special Tools - Differential, Disassembling And Assembling

 VW 407 Press tool
 VW 408 A Press tool
 VW 447 H Thrust disk
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 VW 447 i Thrust disk
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 VW 472/1 Thrust piece

 3138 Drift
 3144 Sleeve
 3296 Tube
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 VW 459 Installation and removal tool

 3 - Kukko 204/2 Puller
 4 - Kukko 22/2 Counter-support
 Kukko 44-2 Two-arm puller
NOTE:
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Fig. 251: Differential, Disassembling And Assembling, Overview
 Removing and installing differential. Refer to Differential, removing and installing.

 Replace both tapered roller bearings.
2 - Shim "S2"
 Note thickness
3 - Outer race for right tapered roller bearing 1)
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 Pulling out. See Extracting tapered roller bearing outer race from transmission housing
 Pressing in. See Pressing tapered roller bearing outer race into transmission housing
4 - Inner race for right tapered roller bearing 1)
 Pulling off. See Pulling off inner race for right tapered roller bearing
 Pressing on. See Pressing on inner race for right tapered roller bearing
5 - Ring gear 1)
 Paired with drive pinion (final drive set)

 Select according to transmission code letters. Refer to Code letters, application, ratios, capacities
 With a mandrel drive off housing. See Driving ring gear off housing
 Install to differential housing. See HEAT THE RING GEAR TO APPROX. 100 ° C and position
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6 - Differential housing 1)
 Allocation
7 - Bolt - 60 Nm + turn 45 ° further
 Always replace
 Lightly tighten bolts then tighten diagonally to specified torque.
8 - Inner race for left tapered roller bearing 1)
 Pulling off. See Pulling off inner race for left tapered roller bearing
 Allocation
can break using excessive force
10 - Outer race for left tapered roller bearing 1)
 Tapping out. See Driving out outer race for left tapered roller bearing out of cover
 Pressing in. See Driving outer race for left tapered roller bearing into cover
 Allocation
11 - Shim "S1"
2:14:24 AM Page 183

 Note thickness
13 - Large differential bevel gear
 Installing. See Installing bevel gears
14 - Shaft for bevel gears
 Remove spring sleeve knocking out with drift
15 - Spring pin
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 For securing shaft for bevel gears
 With annular groove: Removing and installing. See Removing and installing spring sleeve
 Without annular groove: Drive out with mandrel
16 - Small differential bevel gear
17 - One-piece thrust washer
 When installing coat with transmission oil
Extracting tapered roller bearing outer race from transmission housing
Fig. 252: Pulling Outer Race/Tapered Roller Bearing Out Of Transmission Housing
A - Counter support, e.g. Kukko 22/2
2:14:24 AM Page 184

B - Internal puller 46...58 mm, e.g. Kukko 21/7
 Check shims for damage after removing.
Pressing tapered roller bearing outer race into transmission housing
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Fig. 253: Pressing Outer Race/Tapered Roller Bearing Into Transmission Housing
 Install thrust pad VW 472/1 with taper in outer race.

 Support transmission directly beneath bearing support with VW 459/2.
Pulling off inner race for right tapered roller bearing
Fig. 254: Pulling Off Right Tapered Roller Bearing Inner Race
2:14:24 AM Page 185

A - Available two-arm puller, e.g. Kukko 44/2 or Kukko 20/10
NOTE: In the differential housing there is a slot in the bearing seat for applying puller -
A-.
Pressing on inner race for right tapered roller bearing
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Fig. 255: Pressing On Right Tapered Roller Bearing Inner Race
 Heat inner race to approx. 100 ° C, and push to final position.
Pulling off inner race for left tapered roller bearing
Fig. 256: Pulling Off Left Tapered Roller Bearing Inner Race
A - Two arm puller, e.g. Kukko 204/2
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A-.
Installing inner race for left tapered roller bearing
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Fig. 257: Installing Left Tapered Roller Bearing Inner Race
WARNING: Attention:
Wear protective gloves.
Driving out outer race for left tapered roller bearing out of cover
Fig. 258: Driving Out Outer Race Of Left Tapered Roller Bearing From Cover
 Turn webs -A- and -B- out until they sit on outer race within recess in transmission.
Driving outer race for left tapered roller bearing into cover
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Fig. 259: Driving In Outer Race Of Tapered Roller Bearing Into Cover
 Use thrust piece 2050 to press outer race for left tapered roller bearing into cover.
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 Install thrust piece 2050 with taper in outer race.
Driving ring gear off housing
Fig. 260: Driving Out Ring Gear From Housing

Heat the ring gear to approx. 100 ° C and position
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Fig. 261: Installing Ring Gear

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 Install ring gear guide on centering pins -A- (locally made).
 Allow ring gear to cool off slightly before inserting bolts. Then tighten to specified torque.
Installing bevel gears
Fig. 262: Installing Small Differential Bevel Gears

 Lubricate one-piece thrust washer with transmission oil and install.

 Insert large differential bevel gears.
 Insert small differential bevel gears at 180 ° from their final position and rotate into place -arrow-.
 Drive in differential bevel gear shaft into final position and secure.
Removing and installing spring sleeve
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Fig. 263: Pulling Out Spring Pin With Side Cutting Pliers
Removing
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 Using side-cutting pliers pull out spring sleeve with annular groove.
 Using a mandrel drive out from behind the spring sleeve without annular groove.
Installing
 Drive in spring sleeve to stop.
DRIVE PINION AND RING GEAR, ADJUSTING
Drive pinion and ring gear, adjusting
NOTE:  Carefully adjust the drive pinion and ring gear for the service life and
smooth running of the final drive. For this reason, the drive pinion and ring
gear are matched together during manufacturing, and checked to make
sure a good mesh pattern and quiet running. The position of quietest
running is found by moving the drive pinion in an axial direction and at the
same time lifting the ring gear out of the zero-play mesh position by
maintaining the backlash within the specified tolerance.
 The deviation "r" based on master gauge "Ro" is measured and marked on
the outer circumference of the ring gear. Final drive set (drive pinion and
ring gear) may only be replaced together!
Adjusting final drive sets; identification
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Fig. 264: Identifying Gear Set Markings And Adjustment Dimensions
1 - "0937" indicates Oerlikon final drive set with a ratio of 37 : 9.
2 - Pairing number (312) of final drive set
3 - Deviation (tolerance) "r" based on the test machine master gauge used in production. The deviation
"r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm
Ro - Length of test machine master gauge used.
Ro - Ring gear diameter 170 mm = 54.95 mm
2:14:25 AM Page 191

R - Actual dimension between ring gear and face of drive pinion at point with quietest running for this
gear set
Vo - Hypoid offset
Shims position
Fig. 265: Identifying Shim Locations

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NOTE: Adjustment overview when replacing individual components of transmission. .
S1 - Shim for ring gear in cover for final drive
S2 - Shim for ring gear in transmission housing
2:14:25 AM Page 192

S3 - Shim for drive pinion in transmission housing
S4 - Shim for drive pinion in transmission cover
Adjustment overview
NOTE: If repairs have been carried out on the transmission adjust drive pinion, ring
gear or final drive set if components have been replaced which directly effect
the adjustments of the final drive. Refer to following table to avoid unnecessary
adjustments:
To be adjusted:
Ring gear Drive pinion Drive pinion Backlash
Parts replaced: "S1"+"S2" 1) "S3"+"S4" 1) "S4" 1) Refer to Measuring
? Refer to Ring gear, using deviation "r" Refer to Re- backlash
adjusting Refer to Drive determining "S4"
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pinion, adjusting shim when
installing new
transmission cover
Transmission X X X
housing 3)
Transmission cover X
Differential housing X X
tapered roller X X
bearings for drive
pinion
tapered roller X X
bearing for
differential
Final drive set 2) X X X
Cover for final drive X X
1) Shims; installation position.
2) Drive pinion and ring gear; only replace together
3) If the transmission housing is replaced the input shaft also needs to be adjusted. Refer to Input shaft,
adjusting, adjusting input shaft.
Final drive set sequence for re-adjusting
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Fig. 266: Drive Pinion And Gear Ring Adjusting Sequence
When ring gear and drive pinion have to be adjusted, in the interests of a rational sequence, keep to the
following order:
1.) Determine total shim thickness "Stotal" for "S1" +

"S2" (sets pre-load for tapered roller bearings for
differential). Refer to Determining total shim
thickness "Stotal" for shims "S1" + "S2" onward.
drive pinion). Refer to Determining total shim
thickness "Stotal" for shims "S3" + "S4"
3.) Distribute total shim thickness "Stotal" for "S3" +
"S4" so that the distance from center of ring gear to
face of drive pinion is the same as distance "R"
which was determined during production. Refer to
Determining thickness of shim "S3"
"S2" so that specified backlash exists between ring
gear and drive pinion. Refer to Determining
thickness of shim "S2"
NOTE: Overview of components and shims.
Drive pinion, adjusting
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Fig. 267: Identifying Special Tools - Drive Pinion, Adjusting
 Crankshaft seal installing tool VW 204 B Crankshaft seal installing tool

 VW 296 Oil seal extractor
 VW 385 Universal measuring tool
 VW 387 Universal dial gauge holder

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 VW 519 Tube
 VW 792 Assembly device
 3128 Puller

Re-adjustment of the drive pinion is only necessary if the final drive set, tapered roller bearing for drive pinion
or transmission housing is replaced. .
The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test
machine in production. Maximum care and cleanliness are essential when performing repairs and taking
2:14:25 AM Page 196

measurements for achieving good results.
Determining total shim thickness "Stotal" for shims "S3" + "S4"
(adjusting pre-load of tapered roller bearing for drive pinion)
 Differential removed.
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 Without shims press large tapered roller bearing outer race into transmission housing.
 Insert rubber disc-item 40 and pressure plate-item 39 into transmission cover. Refer to Drive pinion,
disassembling and assembling
 Press small tapered roller bearing outer race together with a 1.00 mm thick preliminary shim S4* into
transmission cover.
NOTE: A shim "S4" with a thickness of 1.0 mm is installed for initial measurements. It
is referred to as "S4*" in the following. After determining measurement "e",
2:14:25 AM Page 197

"S4*" will be replaced by the correct shim "S4".
 Pressing on inner race for tapered roller bearing. Refer to Drive pinion, disassembling and assembling.
cardiagn.com
Fig. 271: Identifying Lower Tapered Roller Bearing
 Secure lower tapered roller bearing (arrow). See Determining thickness of circlip
NOTE: Illustration shows drive pinion without gear wheels.
 Insert assembled drive pinion in transmission housing.

 Install transmission cover and tighten bolts to 22 Nm.
 Turn transmission so that transmission cover is downward.
Fig. 272: Pressing Down On Drive Pinion Head Using Removal Tool VW 296
 Press down on face of drive pinion head with lever VW 296 until the tapered roller bearing outer race
contacts the transmission cover.
 Continue pressing on face of drive pinion head, at the same time turn drive pinion 8 turns by hand, so
tapered roller bearing can settle.
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Fig. 273: Installing Dial Gauge (3 Mm Range) And Set To "0" With 2 Mm Pre-Load
 Install dial gauge (3 mm measuring range) and set to "0" with 2 mm pre-load.
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NOTE:  Use dial gauge extension 30 mm long.
 The dial gauge extension must contact the machined surface on the face
of pinion.
 Turn transmission 180 ° so that the transmission cover is upward.

 Rotate drive pinion 5 turns in both directions to settle the tapered roller bearing.
Fig. 274: Turn Transmission 180 Degrees, Settle Tapered Roller Bearing And Read Play On Dial Gauge
 Read play on dial gauge and note reading.
 Measurement in example: 0.45 mm
NOTE: If the measurement has to be repeated, drive pinion must first be rotated
another5 turns in each direction to settle the tapered roller bearing. Reset dial
gauge to "0" with 2 mm pre-load.
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Formula: =
"Stotal" "S4*" + measurement + bearing
pre-load
Example:
Inserted shim "S4*" 1.00 mm
+ Measurement (example) 0.45 mm
+ Bearing pre-load (constant) 0.15 mm
= Total shim thickness "Stotal" for 1.60 mm
"S3" + "S4"
Determining thickness of preliminary shim S3*
Formula: =
"S3*" "Stotal" - "S4*"
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Example:
Total shim thickness "Stotal" for 1.60 mm
"S3" + "S4"
- Inserted shim "S4*" 1.00 mm
= Thickness of shim "S3*" 0.60 mm
 Extract large tapered roller bearing outer race. See Pulling out outer race for large tapered roller
bearing..
 Insert preliminary shim S3* into transmission housing and re-install outer race. See Pressing in outer
race for large tapered roller bearing..
Checking pre-load of tapered roller bearing for drive pinion
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 Rotate drive pinion 5 turns in both directions to settle tapered roller bearing.
NOTE:  If drive pinion cannot be turned by hand, insert a bolt M10 x 20 in drive
pinion head and turn pinion by using a tool on this bolt.
 Remove bolt again.
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Fig. 276: Checking Preload For Tapered Roller Bearing For Drive Pinion
 Install measuring tools and secure with bolt (arrow) to transmission housing.
 Position dial gauge (3 mm measuring range) center on transmission cover and set to "0" with 2 mm pre-
load.
 Loosen transmission cover bolts and turn drive pinion several times.
 If correct shims have been selected dial gauge will now indicate following value:
 0.05... 0.15 mm
 Retighten transmission cover bolts to 22 Nm.

 Remove measuring tools.
 Secure bolt M10 x 20 on drive pinion head and turn drive pinion 8 turns to allow tapered roller bearing to
settle.
 Remove bolt.
Determining dimension "e"
NOTE: Measurement "e" is required to determine the final shim thickness of "S3" and
"S4".
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Fig. 277: Setting Adjusting Rings Of Measuring Bar VW 385/1

 Set adjustment rings of universal mandrel VW 385/1 to following measurements:
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 Dimension b = 75 mm
Fig. 278: Assembling Measuring Bar VW 385/1

 Assemble universal mandrel VW 385/1 according to illustration.
Dial gauge extension A Ro Ring gear diameter

6.5 mm 54.95 170 mm
9.3 mm 59.65 180 mm
 Set master gauge VW 385/30 to Ro according to ring gear diameter and install onto mandrel.
Ring gear diameter 180 mm Ro = 59.65 mm
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 Set dial gauge (3 mm measuring range) to zero with 2 mm pre-load.
Fig. 279: Placing End Gauge On Drive Pinion Face

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 Place end measuring plate on face of drive pinion head.
NOTE: Make sure plate contact surface fits exactly and is free of oil.
Fig. 280: Inserting Measuring Mandrel VW 385/1 Into Housing

 Remove master gauge and insert measuring mandrel in housing.
 With Ro = 54.95 mm, a dial gauge extension = 6.5 mm length must be screwed in instead of dial gauge
extension VW 385/15.
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 The dial gauge faces cover for final drive
 Install cover for final drive and tighten 4 bolts to 22 Nm.

 Using sliding setting ring to pull 2nd centering disc outward until mandrel can still be turned by hand.
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Fig. 281: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion
Shaft Head And Measure Maximum Runout
 Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then
measure maximum deflection (return point).
 Measurement in following example: "e" = 0.26 mm (in red scale on dial)
NOTE: After removing universal mandrel check again that the dial gauge, with master
gauge VW 385/30 in place, indicates "0" with 2 mm pre-load.
 If dial gauge reading is in red scale, subtract dimension "e".

 If dial gauge reading is in black scale, add dimension "e".
 The deviation "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied
as replacement parts and marked on the outer circumference of the ring gear.
Formula:
"S3" = "S3*" + "r" + "e"
("e" in black scale)
"S3" = "S3*" + "r" - "e"
("e" in red scale)
Example:
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+ Deviation "r" 0.38 mm

- Determined value "e" (red scale) 0.26 mm
= Thickness of shim "S3" 0.72 mm
 Determine shim(s) as accurately as possible from table. Part numbers
The following shims are available for "S3"
Shim thickness (mm) 1)

0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if
necessary.
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Formula:
"S4" = "Stotal" - "S3"
Example:
Total shim thickness "Stotal" 1.60 mm

Shim thickness S3 - 0.72 mm
Shim thickness S4 = 0.88 mm

0.49 0.69 0.85
0.57 0.73 0.89
0.61 0.77 0.97
0.65 0.81
necessary.
Performing check measurement
Checking dimension "r"
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 Install drive pinion with determined shims "S3" and "S4" and turn 5 turns in both directions.
Fig. 282: Insert Universal Mandrel And Perform Check Measurement

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 Insert universal mandrel "Determining measurement `e'". Refer to Determining dimension "e", and
perform check measurement.
 Read off dial gauge counterclockwise (red scale).
 If the shims have been correctly selected, the deviation "r" (marked on outer circumference of ring gear)
must be shown within a tolerance of ± 0.04 mm.
Re-determining "S4" shim when installing new transmission cover
Fig. 283: Identifying Dial Gauge Holder VW 387

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Fig. 284: Installation Arbor VW 792

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 Dial gauge
 Dial gauge extension
 Use depth gauge to within at least 5/100 mm.

 Clean housing flange.
Fig. 285: Measuring Difference In Depth On Old And New Transmission Cover
 Measure difference in depth "a" on old and new transmission cover.
Example:
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Depth "a" on old transmission 257.40 mm

cover
Depth "a" on new transmission 257.55 mm
cover
= Difference 0.15 mm
 Install thicker shim "S4" if new transmission cover is deeper.

 Install thinner shim "S4" if the old transmission cover is deeper.
Example:
Previous shim "S4" 0.95 mm

+ Difference 0.15 mm
= New "S4" shim 1.10 mm
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Available shims. Refer to table under The following shims are available for "S4".
 Install outer race for tapered roller bearing with shim "S4" in transmission cover. See Pressing in outer
race for small tapered roller bearing
 Insert completely assembled drive pinion in transmission housing again.
NOTE: Drive pinion can be rotated by simultaneously turning both flange shafts.
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load.
If the correct shims have been selected the dial gauge will now indicate the following value:
 0.05... 0.15 mm

Ring gear, adjusting
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Fig. 287: Identifying Special Tools - Ring Gear, Adjusting
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(Adjusting differential)
 VW 385/17 End measuring plate

 VW 388 Measuring lever
 VW 521 Adjustment tool
 3177 Clamp
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 VW 382/10 Dial gauge extension

 VW 459/2 Installing and removing tool

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(adjusting pre-load of tapered roller bearing for differential)
 Drive pinion removed
 Pull out flange shaft oil seal with oil seal extractor VW 681.
 Remove tapered roller bearing outer race for differential and remove shims. Refer to Differential,
disassembling and assembling.
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 Drive outer race for small tapered roller bearing with shim "S2" into transmission housing. For
measurement purposes use a 1.20 mm thick "S2*" shim (2 shims of 0.60 mm).
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NOTE: For measurement purposes a shim "S2" with a thickness of 1.20 mm is initially
inserted. It is referred to as "S2*" in the following. After determining the
backlash "S2*" will be replaced by the correct "S2".
 Press outer race for tapered roller bearing without shim "S1" into cover for differential.
 Insert differential without drive wheel for speedometer sensor -G22- into transmission housing.
 Install cover for differential with 4 bolts (25 Nm).
 Position transmission so that cover for differential faces up.
 Turn differential 5 turns in both directions to settle the tapered roller bearing.
 Place measuring plate VW 385/17 onto differential.
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Fig. 292: Installing Magnetic Plate 50Mm Dia. VW 385/17 And Dial Gauge
 Assemble measuring equipment, use a 30 mm dial gauge extension.

NOTE: The tip of the dial gauge must be positioned on center of differential.
 Lift differential without turning; read play on dial gauge and note.
 Measurement in following example: 0.62 mm
NOTE:
Fig. 293: Securing Special Tools VW 521/4 And VW 521/12 At Right On

Differential (Housing Side)
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If measurement has to be repeated, differential must again be turned 5 turns in

each direction to settle the tapered roller bearing.
Formula: =
pre-load
Example:
Inserted shim(s) "S2*" 1.20 mm
+ Measurement 0.62 mm
"S1" + "S2"
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Determining thickness of shim "S1*"
NOTE:  The preliminary adjustment shim "S1*" will be replaced with the final shim
"S1" after determining the backlash.
 The total shim thickness "Stotal" remains the same.
Formula:
"S1*" = "Stotal" - "S2*"
Example:
"S1" + "S2"
- Inserted shim(s) "S2*" 1.20 mm
Measuring backlash
 Drive pinion and shims "S3*" and "S4*" installed
 Installing differential with ring gear: S1* is installed on cover side, S2* in transmission housing.
 Install final drive cover and tighten bolts to 25 Nm.
 Turn differential 5 turns in both directions so that the tapered roller bearings settle.
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Fig. 294: Measuring Backlash
 Secure dial gauge holder VW 387 on housing.

 Install dial gauge with dial gauge extension VW 382/10 (6 mm flat).
 Set measuring lever VW 388 to dimension "a":
Dimension "a" Ring gear diameter

67 mm 170 mm
72 mm 180 mm
 Measure play between teeth flanks (backlash) as follows:

 Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
 Set dial gauge to "0" with 2 mm pre-load.
 Turn ring gear back until lying against an opposite tooth flank (backlash).
 Read backlash and note value.

 Turn ring gear 90 ° and repeat measurements another 3 times.
NOTE:
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Fig. 295: Installing Clamp 3177 "A"

 If drive pinion rotates when the differential is turned, install bracket VW 3177 -A- so that backlash can be
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measured exactly.
 Loosen the clamp in order to turn the ring gear.
 Cut-out for large differential bevel gears must point toward drive pinion when differential is inserted.
 With holder 3177 inserted, install differential offset by 180 ° and repeat measurement.
Determining average backlash
 Add four measured values together and divide by four.
Example:
1st measured value 0.28 mm
+ 2nd Measured value 0.30 mm
+ 3rd Measured value 0.30 mm
+ 4th Measured value 0.28 mm
= Sum of measured values 1.16 mm
 Result: The average backlash is 1.16 mm divided by 4 = 0.29 mm
NOTE: If the individual measurements differ by more than 0.06 mm this means that the
installation of the ring gear is not correct or that the final drive set itself is
defective. Check installation, replace final drive set if necessary.
Formula: =
"S2" "S2*" - backlash + lift
Example:
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- Average backlash 0.29 mm
+ Lift (constant) 0.15 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
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necessary.
Formula: =
"S1" "Stotal" - "S2"
Example:
"S1" + "S2"
- Thickness of shim "S2" 1.06 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
necessary.
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 After installing shims "S1" and "S2", turn differential 5 turns in both directions so that tapered roller
bearings settle.
 Measure backlash four times on circumference.
 Specification: 0.12... 0.22 mm
NOTE:  If the backlash is beyond the tolerance, the adjustments must be repeated.
The total shim thickness "Stotal" must not be changed when the
adjustment is repeated.
 The individual measurements must not differ by more than 0.06 mm from
each other.
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34 MANUAL TRANSMISSION - CONTROLS, HOUSING

SHIFT MECHANISM, SERVICING
Shift mechanism, servicing
NOTE: Before working on the selector mechanism, disconnect the Ground strap from
the battery in the engine compartment.
CAUTION: Before beginning repairs on the electrical system:
 Obtain the anti-theft radio security code.

 Switch the ignition off.
 Disconnect the battery Ground (GND) strap.
On vehicles equipped with Audi Telematics by OnStar ® , switch-off
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
the emergency (back-up) battery for the Telematic/Telephone Control
Module prior to disconnecting vehicle battery. Refer to

Cabriolet
.
 After reconnecting vehicle battery, re-code and check operation of

anti-theft radio. Also check operation of clock and power windows
according to article and/or Owner's Manual.
 After reconnecting vehicle battery on vehicles equipped with Audi
Telematics by OnStar ® , switch-on the emergency (back-up) battery
for the Telematic/Telephone Control Module. Refer to

Cabriolet
.
Installation position of gear selector mechanism
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Fig. 51: Installation Position Of Gear Selector Mechanism
1 - Selector rod
2 - Front push rod
3 - Gear selector lever
Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
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Fig. 52: Shift Lever Knob And Protective Boot Remove/Install Components, Shift Lever And - Rear Push
Rod And Shift Lever And - Front Push Rod
I - Removing and installing shift lever knob and protective boot. Refer to Shift lever knob and protective
boot, removing and installing
II - Servicing shift lever and - rear push rod. Refer to Shift lever and rear push rod, servicing
III - Servicing shift lever and - front push rod. Refer to Selector rod and front push rod, servicing
Removing and installing selector mechanism. Refer to Shift mechanism, removing and installing
Adjusting gear selector mechanism. Refer to Shift mechanism, adjusting
Shift lever knob and protective boot, removing and installing
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Fig. 53: Shift Lever Knob And Protective Boot Remove/Install Components
1 - Shift lever knob
 Remove and install together with protective boot

2 - Protective boot
 Remove and install together with shift lever knob

3 - Connector piece
 For locking shift lever knob to shift lever
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 Opening catch. Refer to Fig. 58

 Connects protective boot to shift lever knob
4 - Cover for center console
5 - Damping washer
 Installation position: Convex side upward
 Installation position: Arrow on noise insulation points in direction of travel
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7 - Hex nut, 10 Nm
9 - Hex nut, 10 Nm
10 - Shift lever
 Removing and installing. Refer to Shift mechanism, removing and installing
Shift lever and rear push rod, servicing
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Fig. 54: Shift Lever And Rear Push Rod Remove/Install Components
NOTE: Lubricate mountings and sliding surfaces with polycarbamide grease, part no.
G 052 142 A2.
1 - Shift lever
 Lubricate area around bottom hole with G 052 142 A2

 Lubricate ball with G 052 142 A2 polycarbamide grease
2 - Spacer tube
3 - Circlip
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 Always replace
4 - Washer
 Collar faces ball guide (item 6 Shift lever and rear push rod, servicing)
5 - Rubber ring
6 - Ball guide
7 - Rubber ring
8 - Rear push rod
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 With ball housing
9 - Bolt, 6 Nm
 Qty. 4
Selector rod and front push rod, servicing
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Fig. 55: Shift Rod And Pivot Rod, Overview
1 - Rear push rod
2 - Bolt, 6 Nm
 Qty. 4
4 - Washer
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6 - Clamp
7 - Hex nut, 10 Nm
 Qty. 4
 For shift lever housing to body
8 - Hex nut, 10 Nm
 Self-locking
 Always replace
9 - Shift lever
10 - Spacer tube
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11 - Selector fork
12 - Bolt
13 - Shift lever housing
14 - Tensioning ring
15 - Bellows
 Remove catalytic converter and front heat shield before removing and installing
NOTE:  Carefully pull boot over selector rod

 Place boot on markings of selector rod and push rod
16 - Selector rod
 With selector joint
17 - Bolt, 23 Nm
 Self-locking
 Always replace
 Cannot be removed from bearing bushing on front push rod
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19 - Front push rod
Shift lever with rear push rod, removing and installing
Removing
NOTE: The shift lever knob is removed together with shift lever cover and cover for
center console.
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 Lift cover for center console upward -arrows-.

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cover upward.
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 Remove securing nuts -arrows- for shift lever housing.
This lowers the shift lever housing.
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Fig. 62: Shift Mechanism Housing Fasteners

 Detach push rod, by removing hex socket -head bolt -2-.

 Remove selector rod, by removing hex socket -head bolt -3-.
 Detach complete rear push rod - from shift lever housing -arrows-.
 Remove shift lever with rear push rod - from shift lever housing.
Installing
Installation is carried out in the reverse order of removal, note the following:
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direction of arrow till it stops.
Tightening torques
Rear push rod - to shift lever housing 6 Nm

Selector rod to selector fork/shift lever 25 Nm
Front push rod to rear push rod 25 Nm
Shift lever housing to body 10 Nm
Cover to rear push rod 10 Nm
Shift mechanism, removing and installing
Removing
NOTE: The shift lever knob is removed with shift lever cover and cover for center
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console.

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cover upward.
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 Remove securing nuts for shift lever housing -arrows-.

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Fig. 71: Cross Member Bolts

 Remove rear cross member -arrows-.
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 Remove front cross member -1- -arrows-.

 Remove rear section of exhaust system (rearward of exhaust pipe clamp(s) -2-:
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 Remove hex socket-head bolt of push rod -arrow B-.
 Swivel shift lever housing with selector rod and push rod downward and remove.
Installing
Installation is carried out in the reverse order.
 Push selector rod on so the securing bolt fits in the recess of the selector shaft.

 Tighten screw selector rod (arrow -A-).

 Push rod must be screwed to transmission (arrow -B-).
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direction of arrow as far as stop.
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Tightening torques
Component Nm
Shift lever housing to body 10
Selector rod to transmission 23
Front cross member 55
Rear cross member 55
Noise insulation for shift lever housing to rear push rod 10 Nm
Shift mechanism, adjusting
NOTE: The following are prerequisites for correct shift linkage adjustment:
 Perfect shift linkage operating and transfer elements.

 Shift selector mechanism moves smoothly.
 Transmission, clutch and clutch mechanism must be in good condition.
 Transmission in neutral.
Removing
NOTE: Remove the shift lever knob with shift lever cover and cover for center console.
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cover upward.
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 Lift off trim -1- first in direction of arrow -A- and then pull out in direction of arrow -B-.
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 Lift up damping washer -1- and noise insulation -2- upward.
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 Remove noise insulation from shift lever housing -arrows-.

 Measure distance -a- between the two studs in shift mechanism
NOTE: Measurement is from center of stud to center of stud.
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Fig. 81: Shift Mechanism Measurement And Bolts
 Specification: Dimension a = 85 mm
 In case of deviation, adjust distance -a- as follows:

 Loosen bolt (arrow) for push rod.
 The rear push rod (in shift mechanism) must move back and forth easily on slide.
 Adjust measurement -a- by moving rear push rod (in shift mechanism).
 Tighten bolts for push rod -arrow- to 25 Nm.

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 Remove bolts for selector rod -arrow-.
 The selector rod and shift mechanism connection must move freely
Align shift lever as follows:
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Fig. 83: Centering Bottom Of Shift Lever Centered In Ball Housing
 Center bottom of shift lever centered in ball housing.
 The distance from ball housing to bottom of shift lever -arrows- must be same at all points.
 Shift lever stands vertical in direction of travel.
 Hold shift lever in this position.

 Tighten bolt for selector rod -arrow- to 25 Nm.
NOTE: The shift lever must remain in the same position while the bolt is being
tightened.
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 Install covers and shift lever knob.
Shift lever alignment, checking
 The shift lever must rest in the 3rd/4th gear gate when the transmission is in neutral.
 Depress clutch.
 Check that all gears can be engaged.
 The shift lever must not make contact with cover for center console when selecting gears.
 The shift lever should return by itself from the 5th/reverse gear gate into the 3rd/4th gear gate.
 It should only be possible to engage reverse gear from neutral when shift lever is in 3rd/4th gear gate.
 It must be impossible to change from 5th gear directly into reverse gear.
NOTE: If only 5th and reverse gear cannot be engaged, the 5th and reverse gear
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locking module must be checked and replaced. Refer to Removing and
installing locking module for 5th gear and reverse gear.
TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing
2:16:54 AM Page 24
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Fig. 85: Identifying Special Tools - Transmission, Removing And Installing
 3282 Transmission support

 3282/10 Adjustment plate
 VAG 1383 A Engine/transmission lifter
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Fig. 86: Identifying 10-222A Engine Support Bridge With 10-222A/8 Bracket For Engine
 10-222A Engine support bridge
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Removing

 Note or obtain radio code on vehicles with coded radio.
 Disconnect battery ground strap with the ignition switched off.
Fig. 87: Removing Engine Cover

 Remove engine cover (arrows).
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Fig. 88: Support Bar 10-222 A With Supports 10-222 A/1 Installed On Engine
 Fit support bar 10-222 A with supports 10-222 A/1.
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 Tighten engine slightly using the spindles.
All models:
Fig. 89: Removing Sound Insulation

 Detach noise insulation -arrows-.
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Fig. 90: Removing Noise Insulation Bracket

 Remove bracket for noise insulation -arrow-.
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 Remove tunnel cross member -1- -arrows-.
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 Remove bolts -arrow 1- and -arrow 2- above the right drive shaft and remove heat shield.
 If installed, remove heat shield above the left drive shaft.
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 Remove front exhaust pipe -3- from clamp -2- on:
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 Remove front exhaust system with catalytic converter:
Continued for all models:
Fig. 95: Three Lower Engine And Transmission Connecting Bolts

 Remove the three lower engine and transmission connecting bolts -arrow-.
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 Remove the drive shafts -1- from the flange shafts and tie these up.
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NOTE: Do not damage protective coating on drive shafts.
 Support transmission with engine and transmission lifter VAG 1383 A.

 Remove bolts -2- and then bolts -3- on tunnel cross member.
 Remove the two nuts -4- and detach tunnel cross member -2-.
 Lower engine and transmission lifter VAG 1383 A and place to one side.
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 Remove hex socket-head bolt on push rod -arrow B-.
Fig. 99: Identifying Connectors For Vehicle Speed Sensor (VSS) And Back-Up Lights
 Disconnect connector off speedometer sensor -arrow A-.

 Disconnect connector on reversing light switch (multi-function sensor) -arrow B-.
 Disconnect all other electrical connections and ground wires from transmission and from the engine and
transmission securing bolts.
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Fig. 100: Location Of Engine Speed (RPM) Sensor G28 On Coupling Housing
 If installed, remove engine speed (RPM) sensor -G28- on left of transmission -arrow- and lay to one side.
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Fig. 101: Removing Starter Bolt
 Remove starter from engine and transmission and secure.
NOTE: Do not disconnect starter cables.
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 Remove lower engine and transmission connecting bolts, except for bolts -arrow A- and -arrow B-.
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Fig. 103: Transmission Support 3282 Attachment Plate
 Set the transmission support 3282 for removing the manual 012 with adjustment plate 3282/10 and attach
to transmission lifter VAG 1383 A.
A - Support elements
NOTE:  Support elements -A- are shown in schematic form, arrow -B- points in
direction of travel.
 Adjustment plate 3282/10 only fits in one position.
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Fig. 104: Setting Transmission Jack Under Vehicle

 Place transmission lifter under vehicle. Arrow -B- (See Fig. 103) on adjustment plate points in direction
of travel.
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Fig. 105: Aligning Adjustment Plate Parallel To Transmission And Lock Safety Support On
Transmission
 Align adjustment plate parallel to transmission and lock safety support -arrow- on transmission.
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 Remove engine and transmission connecting bolts (arrows -A- and -B-).
 Push transmission off dowel sleeves and lower carefully with transmission lifter VAG 1383 A just far
enough to access the slave cylinder.
NOTE: When lowering transmission make sure hydraulic line and hose to slave
cylinder is not damaged.
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 Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect lines.
NOTE: Do not depress clutch pedal after removing slave cylinder.
 Lower transmission.
NOTE: When lowering transmission make sure there is sufficient clearance for drive
shafts.
Secure transmission to repair stand with transmission support VW 353 and retaining plate VW 309 to carry out
repairs.
2:16:54 AM Page 36
Fig. 108: Transmission Mount

 If the transmission is exchanged, the transmission mount must be transferred to the exchange
transmission.
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Transmission, transporting
Fig. 109: Transmission Support Jig. 3336

 3336 transmission lifting beam
Transmission lifting beam can be used to transport transmission and when setting up transmission support 3282.
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Fig. 110: Bolting Transmission Support Jig. 3336 To Transmission Housing

 Bolt transmission lifting beam 3336 to clutch housing.
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Fig. 111: Adjust Support Jig On Sliding Piece Using Locking Pin
 Set support arm in slide with locking pin (arrow).
 No. of holes visible = 17
 Lift transmission with workshop crane and transmission lifting beam 3336.
Installing
 Clean input shaft splines and lightly grease with G000 100 grease.
The clutch plate must slide easily back and forth on input shaft.
 Lightly coat contact surface on push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
2:16:54 AM Page 38
 Check whether dowel sleeves for centering engine and transmission in cylinder block have been installed.
 If installed, make sure that intermediate plate is correctly positioned on engine.
 Check clutch release bearing for wear and replace.
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 If plastic ring on release bearing is detached, adhere this back onto bearing ring with adhesive AMV 195
KD1 01.
Three right-angled lugs -arrows- on plastic ring engage in the recesses on bearing ring.
If ridges are deeper than 0.5 mm, replaced release bearing.
 All threaded holes into which self-locking bolts are installed, must be cleaned of locking fluid residue
with a thread tap.
 Replace all self locking nuts.

 Lift transmission until clutch slave cylinder with bracket for hose and line can be installed (arrow).
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 Install lower engine, transmission and starter mounting bolts and install starter.
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 Install tunnel cross member onto transmission mount -4-.

 Install tunnel cross member onto body. First install bolts -3- and then bolts -2-.
 Check shift mechanism adjustment, adjust. Refer to Shift mechanism, adjusting.
 Checking oil level in manual transmission. Refer to Oil level in manual transmission, checking.
 Connect battery.
 After connecting battery, enter anti theft code for radio.
Refer to Operating instructions for radio
NOTE: On re-connecting battery, remember to check and re-activate vehicle equipment

(radio, clock, convenience electronics, etc.).
Refer to
Tightening torques
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Fig. 115: Identifying Engine/Transmission Mountings (Automatic/Manual Transmission)

Attachment of 4-cylinder engine to transmission
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Item Bolt Nm
1, 3, 4 M12 x 75 65
2 M12 x 90 65
5, 11 M12 x 110 65
7... 10 M10 x 45 45
11 M12 x 130 65
A: Dowel sleeves for centering
Transmission mount with mount to transmission -arrows- 23 Nm
1 - Drive shaft to flange shaft M8 40 Nm

M10 70 Nm
2 - Tunnel cross member to body M10 55 Nm
1)
3 - Tunnel cross member to body 1) 110 Nm
+ 90 °
4 - Tunnel cross member to transmission mounting 23 Nm
1) Always replace bolt with washer
Component Nm
Engine speed (RPM) sensor -G28- 10
Clutch slave cylinder to transmission1) 23
Selector joint to transmission 1) 23
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Tunnel cross member to body 55

Bracket for noise insulation to subframe 10
1) Replace bolt.
OIL LEVEL IN MANUAL TRANSMISSION, CHECKING
Oil level in manual transmission, checking
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Fig. 116: Identifying Triple Square Socket Driver 3357
 3357 socket attachment

NOTE:  The vehicle must be level when checking transmission oil level. This work
2:16:55 AM Page 42
is best performed over an inspection pit or using a 4 -column lifting

platform.
 The oil filler plug is on the left of the transmission below the speedometer
sensor; it may be concealed by the heat shield for the drive shaft.
 Remove oil drain plug using special tool 3357.
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 To check oil level, remove oil filler plug (arrow).

 Check oil level using a shop-built tool, e.g. a piece of angled wire.
 Specification: Oil level 7 mm below bottom edge of oil filler hole
NOTE: In service centers filling to lower edge of filler hole is also permissible.
 Fill with gear oil if necessary: Specification. Refer to Code letters, application, ratios, capacities.

 Install oil filler plug.
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Tightening torque
Component Nm
Oil filler plug 25
TRANSMISSION, DISASSEMBLING AND ASSEMBLING
Transmission, disassembling and assembling
Assembly sequence. Refer to Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion,
selector rods and transmission cover, removing and installing
Transmission overview
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Fig. 120: Transmission, Overview

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1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - Reverse gear
 Removing and installing reverse idler. Refer to Reverse idler gear, removing and installing
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9 - Input shaft
10 - Drive pinion
11 - Ball bearing
 Adjusting. Refer to Input shaft, adjusting adjusting input shaft
12 - Differential
 Removing and installing. Refer to Differential, removing and installing

Assembly overview
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Fig. 121: Transmission, Assembly Overview, I and II
I - Removing and installing input shaft ball bearing and multi-function sensor. Refer to Input shaft ball
bearing and multi-function sensor, removing and installing
II - Removing and installing input shaft, drive pinion, selector rods, transmission cover. Refer to Input
shaft, drive pinion, selector rods and transmission cover, removing and installing
Input shaft ball bearing and multi-function sensor, removing and installing
2:16:55 AM Page 46
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 With differential and flange shafts

 Removing and installing flange shafts. Refer to Flange shaft oil seal, replacing
 Removing and installing differential. Refer to Differential, removing and installing
 Removing and installing speedometer sensor and drive wheel. Refer to Speedometer sensor and drive
wheel, removing and installing
 Breather installation position. See Installation position of breather
 Self-locking
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 Always replace
3 - Guide sleeve
 With O-ring and seal for input shaft. Refer to Clutch release mechanism, servicing
4 - Dished washer
5 - Circlip
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6 - Ball bearing
7 - Circlip
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8 - Input shaft

 Servicing input shaft bearings. Refer to Input shaft, disassembling and assembling
9 - Bolt
10 - Tab washer
 For multi-function sensor
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11 - Multi-function sensor
12 - Connector for multi-function sensor
13 - Bolt - 10 Nm
14 - Cover for selector shaft
 Removing and installing. Refer to Shift mechanism in transmission, disassembling and assembling
gear
Installation position of breather
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Fig. 124: Identifying Installed Position Of Breather
The breather must project 21 mm out of housing, after being pressed in.
Input shaft, drive pinion, selector rods and transmission cover, removing and installing
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Fig. 125: Input Shaft, Drive Pinion, Shift Rods And Transmission Cover, Overview
1 - Selector rod with selector fork for 3rd and 4th gear

assembling
 Replacing mounting bushings. Refer to Shift mechanism in transmission, disassembling and
assembling
2 - Input shaft

 Servicing input shaft bearings. Refer to Input shaft, adjusting
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4 - Washer
5 - Relay shaft
6 - Washer
8 - Selector shaft

 Replace selector shaft sealing ring. Refer to Shift mechanism in transmission, disassembling and
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assembling
9 - Detent segment
 With collar to secure the detent segment spring
11 - Selector rod with selector fork for 1st/2nd/5th and reverse gear

assembling
 Removing and installing ball sleeves. Refer to Removing and installing ball sleeve
12 - Drive pinion

 Servicing drive pinion bearings. Refer to Drive pinion, disassembling and assembling
 Removing and installing oil collector. Refer to Removing and installing oil collector
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 Match components according to transmission code letters
Removing and installing oil collector
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Fig. 126: Identifying Oil Collector Tray
Removing
 Turn the oil collector arrow- and then pull out.
Installing
 Push oil collector into transmission cover until it snaps in place.
 Installation position: Oil collector faces upward in transmission cover
Ball bearing for input shaft, multi-function sensor, input shaft, drive pinion, selector rods and transmission cover,
removing and installing
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Fig. 127: Identifying Special Tools - Disassembly And Assembly
 VW 309 Holding plate

 VW 353 Transmission support
 3235 Press Device
 3357 Triple square socket driver
 VAG 1582 Tapered roller bearing puller

 VAG 1582/2 Gripping piece
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 Sealant AMV 188 001 02
NOTE:  It is not necessary to remove the differential to remove the above-

mentioned components.
 Removal is only necessary when adjustments have to be carried out
adjustment overview:
Removing

 Drain gear oil, using socket attachment 3357.
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Fig. 130: Securing Transmission To Assembly Stand

 Secure transmission to repair stand.
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 Detach clutch release lever -A- with release bearing.
NOTE: Cover input shaft splines with a shrink-fit hose to protect oil seal, before pulling
off guide sleeve.
 Remove guide sleeve -B-.

 Remove dished washer -C-.
 In front of input shaft ball bearing remove circlip -D-.
replaced.
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Fig. 132: Pulling Input Shaft Ball Bearing Out Of Transmission Housing
 Pull the input shaft ball bearing out of the transmission housing.
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 Remove the circlip (arrow) behind the input shaft ball bearing.
replaced.
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 Remove transmission cover -A- from transmission housing -B-.
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 Remove bolts (arrows) and pull out the multi-function sensor.

 Remove relay shaft bolts (arrows).
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 Remove detent segment (arrow) and swivel it out.
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Fig. 138: Identifying Input Shaft, Drive Pinion, Relay Shaft, Shift Rods With Selector Shaft And Selector
Forks
 The input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and selector
forks -E- must be carefully pulled out together.
Installing
NOTE: If input shaft ball bearing, input shaft or the transmission housing are replaced,
it is necessary to re-determine the thickness of circlips for input shaft. Refer to
Input shaft, adjusting, adjusting input shaft.
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Fig. 139: Swing Transmission Housing Into Position Shown

 For easier installation of following components, swing transmission housing into the position shown.
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Fig. 140: Assemble Input Shaft, Drive Pinion, Relay Shaft, Selector Rods With Shift Rod And Selector
Forks
 Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with selector shaft and
selector forks -E-.
 Install these components together into transmission housing.
NOTE: Relay shaft -C- and selector shaft can also be installed later. Refer to Fig. 143.
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Location of shift mechanism in transmission
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4 - Relay shaft
6 - Selector shaft
NOTE: Shown in illustration with input shaft and drive pinion removed.
Fig. 142: Move Transmission To Engage 3rd Gear

 Turn transmission housing and engage 3rd gear (direction of arrow).
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Fig. 143: Installing Relay Shaft And Shift Rod

 Install relay shaft -A-.
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 Insert selector shaft -B- sideways into hole in transmission housing and assemble into mounting eye.
 Turn the selector shaft in direction of arrow.

 Insert the detent segment and tighten bolt (arrow).
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 Install relay shaft bolts (arrow).
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 Replace O-ring for multi-function sensor.

 Carefully insert multi-function sensor and tighten (arrow).
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Check that dowel sleeves for transmission cover -A- are installed in transmission housing -B-.

 Install transmission cover onto transmission housing.
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 Install rear input shaft ball bearing circlip (arrow).

 Slide the ball bearing onto input shaft.
 Installation position: Closed side of ball cage faces toward transmission housing
Fig. 149: Pressing In Ball Bearing

 Press in ball bearing:
 Slide thrust pad -A- on press-in tool onto input shaft.

 Position press-in tool behind splines for clutch plate.
 Install bolts -B- until they make contact.
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 The bolts bear against the indentations in thrust pad -A-.
 Press in ball bearing onto its seat by alternately tightening the bolts (1/2 turn at a time).
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 Install front circlip -D- for the input shaft ball bearing.
 Install dished washer -C-.
 Installation position: Convex side toward guide sleeve -B-
NOTE: Before installing guide sleeve, cover input shaft splines with a shrink-fit hose to
protect oil seal.

 Install guide sleeve -B- for release bearing.

 Install clutch release lever -A- and release bearing.
SHIFT MECHANISM IN TRANSMISSION, DISASSEMBLING AND ASSEMBLING
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Shift mechanism in transmission, disassembling and assembling
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Fig. 152: Identifying Special Tools - Shift Mechanism On Transmission Side, Disassembling And
Assembling
 VW 295 Drift
 VW 295 A adapter
 VW 420 Tube
 VW 423 Tube
 VW 472/2 Spacer sleeve
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Fig. 153: Slide Hammer-Multi-Purpose Tool Set VW 771

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Fig. 154: Kukko 21/2 Internal puller, Kukko 21/4 Internal puller, Kukko 22/2 Counter support
NOTE: Installation position of complete shift mechanism in transmission. See

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Fig. 155: Shift Mechanism In Transmission, Overview
gear
3 - O-ring
 Always replace
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5 - Washer
6 - Relay shaft
7 - Washer
9 - Detent segment
11 - Spring pin
12 - 5th and reverse gear selector fork
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for selector rod
13 - Selector rods for 1st/2nd and 5th/reverse gear
14 - Ball sleeve
 Removing and installing. Refer to Removing and installing ball sleeve
15 - Selector fork, 1st and 2nd gear
16 - Relay lever
for selector rod
17 - Mounting bushing for 3rd and 4th gear
 Pulling out. Refer to Pulling out mounting bushing for 3rd and 4th gear selector rod
 Driving in. Refer to Driving mounting bushing for 3rd and 4th gear selector rod home
18 - Ball sleeve
 Pry off the selector rod with a screwdriver

 Press on the selector rod
19 - Selector rod for 3rd and 4th gear
20 - Selector fork, 3rd and 4th gear
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21 - Spring pin
22 - Cover plate
 For selector shaft
24 - Selector shaft
25 - Sealing ring
 Pry out with screwdriver

 Insert using tube VW 420
 Installation position. See Installation position of oil seal.
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Installation position of 5th and reverse gear selector fork and follower for selector rod
Fig. 156: Identifying Installed Position For 5th/Reverse Gear Shift Fork And Coupling Plate For Shift
Rod
Removing and installing ball sleeve
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Fig. 157: Removing/Installing Ball Sleeve

Pulling out mounting bushing for 3rd and 4th gear selector rod
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Fig. 158: Removing Bushing For 3rd And 4th Gear Shift Rod
A - Internal puller 22... 28 mm, e.g. Kukko 21/4, in conjunction with multi-purpose tool VW 771
Driving mounting bushing for 3rd and 4th gear selector rod home
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Fig. 159: Driving In Bushing For 3rd And 4th Gear Shift Rod
Installation position of oil seal
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Fig. 160: Identifying Installed Position Of Sealing Washer
 Fill space between sealing and dust lips with multi-purpose grease.
 Insert oil seal using tube VW 420

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4 - Relay shaft
6 - Selector shaft
Removing and installing locking module for 5th gear and reverse gear
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 Remove heat shield - arrow 2- above right-hand drive shaft.

 Detach heat shield -arrow 1- above right-hand drive shaft and pivot downward.
Fig. 163: Identifying Gear Lock

 Remove locking module -arrow-.
Assembling locking module:
2:16:55 AM Page 73

 Insert spring -1- into housing -2-, while exerting light pressure, turn spring to the left until it locates in the
base of the housing.
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 Insert bushing -3- into the spring so that the bent end of the spring locates in the designated groove.
 Push bushing -3- against spring and turn approx. one turn to left, until the lug on the bushing aligns with
the groove in the housing -2-.
 Press lug on bushing -3- onto stop in the groove in the housing -2-.
 Turn bushing -3- clockwise and release; bushing -3- springs to installation position.

Installation position of bushing:
The lug (arrow -A-) on the bushing must always be opposite the groove in the housing (arrow -B-).
Check installation position:
 Turn bushing counterclockwise and release.
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 The bushing must spring back; the lug must lie against the stop -direction of arrow A-
Fig. 166: Installed Position Of Complete Gear Lock In Transmission

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Installation position of complete locking module in transmission:
The recess (arrow -A-) faces bolt (arrow-B-)
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35 MANUAL TRANSMISSION - GEARS, SHAFTS

INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
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 VW 295 A Needle bearing drift
 VW 407 Punch
2:18:15 AM
2:18:19 Page 1
 VW 408 A Punch
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 VW 415 A Tube
 VW 416 B Tube
 VW 447 i Thrust pad
 VW 771 Slide hammer - complete set
 30-100 Press tube

 40-105 Thrust piece
2:18:15 AM Page 2
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 VW 222 A Mandrel
 30-24 Mandrel
 40-202 Press tool
NOTE:
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Fig. 170: Input Shaft, Overview
 When installing new gears or the input shaft consult technical data. Refer to Code letters, application,
ratios, capacities.
 If -items 2, 4 or 6 under Input shaft, disassembling and assembling are replaced the position of the ball
bearing will be affected. The input shaft should be re-adjusted. Refer to Input shaft, adjusting.
1 - Circlip
 Mark
 Determining thickness. Refer to Input shaft, adjusting adjusting input shaft
2 - Ball bearing
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3 - Circlip
 Mark
 Installation position Installation position of circlips item 2
 Determining thickness. Refer to Input shaft, adjusting
5 - Needle bearing
 Secured with bolt. See Remove securing bolt -arrow- for needle bearing
 Driving out. See Driving out needle bearing
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 Installation position. See Installation position of needle bearing
 Pressing in. See Pressing in needle bearing
 Locking. See Screwing in securing bolt -arrow-
6 - Input shaft
 With oil feed sleeve

 Knocking in oil feed sleeve. See Driving oil feed sleeve into input shaft
7 - Needle bearing for 3rd gear
 Mark
8 - 3rd speed sliding gear
9 - Spring
 Insert in 3rd speed sliding gear. See Inserting spring in sliding gear
10 - Synchro-ring for 3rd gear
11 - Circlip
 Mark
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12 - Synchro-hub for 3rd and 4th gear
 High collar faces 3rd gear

 Pressing off. See Pressing off synchro-hub for 3rd and 4th gear
 Pressing on. See Pressing on synchro-hub for 3rd and 4th gear
13 - Circlip
 Mark
 If synchro-hub is replaced re-determine thickness. See Determining thickness of circlip
14 - Locking collar for 3rd and 4th gear
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 Installation position. See Installation position of locking collar
16 - Spring
 Insert in 4th speed sliding gear. See Inserting spring in sliding gear
 Mark
19 - 5th gear wheel

20 - Circlip
 Mark
 If the 5th gear wheel is replaced re-determine thickness. See Determining thickness of circlip
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21 - Roller sleeve
 Replace
 Pulling out. See Pulling out roller sleeve
 Installation position. See Installation position of roller sleeve
 Tapping in. See Driving in roller sleeve
22 - Sleeve
 Made of plastic
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Remove securing bolt -arrow- for needle bearing

 Remove securing bolt -arrow-.
Driving out needle bearing
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Fig. 172: Driving Out Needle Bearing

Installation position of needle bearing
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Fig. 173: Installation Position Of Needle Bearing
Distance -a- from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm
NOTE: Measure distance from top edge of straight-edge and subtract the width of the
straight-edge from the measured distance.
Pressing in needle bearing
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Fig. 174: Pressing In Needle Bearing

Screwing in securing bolt -arrow-
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 Tighten to 25 Nm
Driving oil feed sleeve into input shaft
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Fig. 176: Driving In Oiling Sleeve Into Input Shaft

Item Oil feed sleeve dia. Fitting tool
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A 14 mm VW 222 A
B 16 mm 30-24
Flanged edge on oil feed sleeve faces toward fitting tool
 Insertion depth:
3.5 mm below top edge
Pulling out roller sleeve
Fig. 177: Removing Roller Sleeve

Before installing internal extractor, the plastic sleeve inside the roller sleeve must be destroyed.
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Installation position of roller sleeve
Fig. 178: Installed Position Of Roller Sleeve

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Driving in roller sleeve
Fig. 179: Driving In Roller Sleeve

2:18:16 AM Page 11

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Pressing off synchro-hub for 3rd and 4th gear
Fig. 181: Pressing Off Synchro-Hub For 3rd And 4th Gear

 Press 3rd gear synchro ring (arrow) toward 3rd gear wheel, then install separating device -A-.
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C-.
 Add the measured values and divide by 3.
The average value must not be less than 0.5 mm.
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Fig. 184: Identifying Installed Positions Of Circlips
 Circlips -1- and -2- secure the input shaft ball bearing Adjusting input shaft: Refer to Input shaft,
adjusting.
Thickness 2.00 mm. Identification: Brown color.
Determining thickness table on. Refer to Available circlips for 3rd and 4th gear synchro-hubs
Determining thickness table on. Refer to Available circlips for 5th gear wheel.
2:18:16 AM Page 14
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 Determine thickest circlip that will just fit and install it.
 Determine circlip as accurately as possible from table. Part numbers
Available circlips for 3rd and 4th gear synchro-hubs

1.90 1.96 2.02
1.93 1.99 2.05
Available circlips for 5th gear wheel

1.90 1.96 2.02
1.93 1.99
Pressing on synchro-hub for 3rd and 4th gear
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Fig. 186: Pressing On Synchronizer Hub For 3rd And 4th Gears
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Installation position of locking collar
3
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Chamfered edge -arrow 1- faces 4th gear
Small shoulder -arrow 2- faces 3rd gear
Large shoulder -arrow 3- faces 4th gear
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 Heat 5th gear wheel to approx. 100 ° C before pressing on.
High collar faces reverse gear
INPUT SHAFT, ADJUSTING
Input shaft, adjusting
(determining circlips for input shaft)
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Fig. 189: Press Tube 30-100Identifying Special Tools - Oil Pump/Front Sealing Flange, Drive Chain And
Chain Sprocket For Oil Pump, Removing And Installing
30-100 Press tube
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
Fig. 190: Spacer Gauge 3167

 3167 Spacer gauge

 Depth gauge
It is necessary to readjust input shaft when the:
 Transmission housing
 Input shaft
or
 Ball bearing
are replaced.
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Fig. 191: Placing Transmission Housing Over Input Shaft Onto Spacer Gauge
 Clamp input shaft in vice using soft jaws -A-.
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 Place distance gauge 3167 onto 3rd gear sliding gear.
 Place transmission housing over input shaft onto the distance gauge.
Fig. 192: Determining Circlip Thickness, Measuring Value "a"

 Place depth gauge onto transmission housing and measure to the lower circlip groove in the input shaft.
 Measurement in following example: -a- = 28.50 mm
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Fig. 193: Determining Circlip Thickness, Measuring Value "b"

 Place depth gauge onto transmission housing and measure to seat surface for ball bearing.
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 Measurement in following example: -b- = 26.80 mm
Determining circlip x behind the input shaft ball bearing.
Formula:
"x" = Dimension "a" - dimension "b"
Example:
Dimension "a" 28.50 mm
- Dimension "b" 26.80 mm
= Dimension "x" (thickness of 1.70 mm
circlip)
Available circlips
Dimension "x" Thickness (mm)

1.48... 1.56 1.54
1.57... 1.65 1.63
1.66... 1.74 1.72
1.75... 1.83 1.81
1.84... 1.92 1.90
1.93... 2.01 1.99
2.02... 2.10 2.08
2.11... 2.20 2.17
2.21... 2.27 2.25
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2.28... 2.35 2.33
Determining the circlip in front of the input shaft ball bearing
 Knock rear circlip (as calculated) and ball bearing onto input shaft with fitting sleeve 30-100.
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Fig. 194: Input Shaft And Thickest Circlip Which Can Still Just Be Installed
 Determine the thickest circlip which will still fit.

Available circlips

1.45 1.72 1.99
1.54 1.81 2.08
1.63 1.90 2.17
DRIVE PINION, DISASSEMBLING AND ASSEMBLING
Drive pinion, disassembling and assembling
2:18:16 AM Page 21
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Fig. 195: Identifying Special Tools - Output Shaft


 VW 415 A Tube
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 Crankshaft seal installing tool VW 204 B

 VW 421 Tube
 VW 455 Pressing-on sleeve
 VW 519 Tube

 2010 Tube
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 3128 Puller

NOTE:
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Fig. 198: Exploded View Drive Pinion Up To Transmission Manufacture Date 22
06 3
 When installing new gears or the final drive set consult technical data. Refer to Code letters,
application, ratios, capacities.
2 - Shim "S3"
3 - Outer race for large tapered roller bearing 1)
 Pulling out. See Pulling out outer race for large tapered roller bearing
 Pressing in. See Pressing in outer race for large tapered roller bearing
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4 - Drive pinion1)
 Is mated with ring gear, replace together as a set

 Adjusting ring gear and drive pinion. Refer to Drive pinion and ring gear, adjusting
5 - Inner race for large tapered roller bearing 1)
 Always replace
 Pressing off. See Pressing off inner race for large tapered roller bearing
 Pressing on. See Pressing on inner race for large tapered roller bearing
6 - Circlip
 Mark
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 Re-determine thickness if tapered roller bearing is replaced. See Determining thickness of circlip
8 - 1st gear sliding gear
9 - Spring
 Insert in 1st gear sliding gear. See Inserting spring in sliding gear
10 - Synchro-ring for 1st gear
11 - Synchro-hub for 1st and 2nd gear
 Pressing off. See Pressing off synchro-hub for 1st and 2nd gear
 Pressing on. See Pressing on synchro-hub for 1st and 2nd gear
12 - Circlip
 Mark
 Re-determine if the synchro-hub is replaced. See Determining thickness of circlip
13 - Needle bearing for 2nd gear
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14 - Locking collar, 1st and 2nd gear
 Installation position. See Installation position of locking collar for 1st and 2nd gear
15 - Synchro-ring for 2nd gear
16 - Spring
 Insert in 2nd gear sliding gear. See Inserting spring in sliding gear
17 - 2nd gear sliding gear
18 - Circlip
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 Mark
19 - 3rd gear wheel
 Pressing off. See Pressing off 3rd gear wheel

 Shoulder points to 4th gear
 Pressing on. See Pressing on 3rd gear wheel
20 - Circlip
 Mark
 Re-determine thickness If the 3rd gear wheel is replaced. See Determining thickness of circlip
21 - 4th gear wheel

 Shoulder points to 3rd gear
22 - Circlip
 Mark
 Re-determine thickness if the 4th gear wheel is replaced. See Determining thickness of circlip
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23 - Needle bearing
25 - Spring
 Insert in 5th gear sliding gear. See Inserting spring in sliding gear
27 - Circlip
 Mark
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28 - 5th gear and reverse gear synchro-hub
 Pressing off. See Pressing off 5th gear and reverse gear synchro-hub
 Pressing on. See Pressing on 5th gear and reverse gear synchro-hub
29 - Circlip
 Mark
 If the synchro-hub is replaced re-determine. See Determining thickness of circlip
30 - Needle bearing
 For reverse gear
31 - Locking collar for 5th and reverse gear
 Installation position. See Installation position of locking collar for 5th and reverse gear
32 - Reverse gear synchro-ring
33 - Spring
 Insert in reverse gear sliding gear. See Inserting spring in sliding gear
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34 - Reverse gear sliding gear
35 - Inner race for small tapered roller bearing 1)
 Pressing off. See Pressing off inner race for small tapered roller bearing
 Pressing on. See Pressing on inner race for small tapered roller bearing
36 - Socket
 To secure small tapered roller bearing outer race

 Pulling out. See Pulling out securing bushing for small tapered roller bearing outer race
 Need not be fitted after the small tapered roller bearing has been replaced.
37 - Outer race for small tapered roller bearing 1)
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 Pulling out. See Pulling out outer race for small tapered roller bearing
 Pressing in. See Pressing in outer race for small tapered roller bearing
38 - Shim "S4"
39 - Pressure plate
40 - Rubber disc
 Compensates length variations

 To remove, insert self-tapping screw center and pull out washer on self-tapping screw.
 Use components according to the transmission code letters. Refer to Code letters, application, ratios,
capacities.
Pulling out securing bushing for small tapered roller bearing outer race
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Fig. 199: Pulling Off Securing Bushing For Small Tapered Roller Bearing Outer Race
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Pulling out outer race for small tapered roller bearing
Fig. 200: Pulling Off Outer Race Of Small Tapered Roller Bearing
 Screw special tool VW 771/40 into pressure plate

 Install multi-purpose tool VW 771 and pull outer race out via pressure plate.
Pressing in outer race for small tapered roller bearing
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Pulling out outer race for large tapered roller bearing
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Fig. 202: Pulling Out Double Tapered Roller Bearing Outer Race
 Remove differential. Refer to Differential, removing and installing.

 Place pressure piece of puller 3128 below the outer race.
 Install threaded spindle and pressure bearing of assembly device 3301 with pressure plate VW 401 onto
When tightening bolt the outer race will be pulled out of housing.
Pressing in outer race for large tapered roller bearing
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The smaller diameter of special tool VW 204 b faces outer race.
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Pressing off inner race for small tapered roller bearing
Fig. 204: Pressing Off Tapered Roller Bearing Inner Race

 Press off inner race with reverse gear sliding gear.
Pressing off 5th gear and reverse gear synchro-hub
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Fig. 205: Pressing Off Synchronizer Hub For 5th And Reverse Gear
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 Press off synchro-hub with 5th gear sliding gear.

Pressing off 3rd gear wheel
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Fig. 207: Pressing Off 3rd Gear

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 Pressing off 3rd gear wheel with 2nd gear sliding gear.
Pressing off synchro-hub for 1st and 2nd gear
Fig. 208: Pressing Off Synchronizer Hub For 1st And 2nd Gears

 Press off synchro-hub with 1st gear sliding gear.
Pressing off inner race for large tapered roller bearing
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Fig. 209: Pressing Off Double Tapered Roller Bearing Inner Race
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The outer race -A- must be installed to press off the inner race.
Pressing on inner race for large tapered roller bearing
Fig. 210: Pressing On Inner Race For Large Tapered Roller Bearing
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 Determine thickest circlip which will still fit and install it.
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The circlips for synchro-hubs and individual gear wheels should also be determined as shown for tapered roller
bearing.
Available circlips and part numbers

The circlips for synchro-hubs, needle roller bearings and individual gear wheels should also be determined.
Refer to Determining thickness of circlip.
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 Circlip -1- secures the inner race for tapered roller bearing.

2.00 2.06 2.12
2.03 2.09 2.15
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 Circlip -2- secures the 1st and 2nd gear synchro-hub.

1.90 1.96 2.02
1.93 1.99
 Circlip -3- secures the needle bearing for 2nd gear sliding gear.

2.50
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 Circlip -4- secures the 3rd gear wheel.

1.90 1.98 2.06
1.94 2.02

1.86 1.94
1.90 1.98
 Circlip -6- secures the needle bearing for 5th gear sliding gear.
Distinguishing features. color - brown

2.00
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 Circlip -7- secures the synchro-hub for 5th gear and reverse gear.
Distinguishing features. color - blue

1.90 1.96 2.02
1.93 1.99 2.05
 Determine circlips according to table: Part numbers

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C-.
 Add measured values and divide by 3.
Calculated value must not be less than 0.5 mm.
Pressing on synchro-hub for 1st and 2nd gear
Fig. 218: Pressing On Synchronizer Hub For 1st And 2nd Gears
High inside collar faces 2nd gear
Installation position of locking collar for 1st and 2nd gear
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Fig. 219: Identifying Installed Position Of Operating Sleeve For 1st And 2nd Gear
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Chamfered edge -arrow 1- faces 2nd gear
Shoulder -arrow 2- faces 1st gear
Pressing on 3rd gear wheel
Fig. 220: Pressing On 3rd Gear

Groove on gear wheel faces 4th gear
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Pressing on 5th gear and reverse gear synchro-hub
Fig. 222: Pressing On Synchronizer Hub For 5th And Reverse Gear
High inside collar faces 5th gear
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NOTE: Large inner diameter in special tool 2010 faces synchro-hub.
Installation position of locking collar for 5th and reverse gear
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3
 Make sure locking collar is correct version for reverse gear wheel. See Selecting correct locking collar
for reverse gear wheel
Chamfered edge -arrow 1- faces reverse gear
Small shoulder -arrow 2- faces 5th gear
Large shoulder -arrow 3- faces reverse gear
Pressing on inner race for small tapered roller bearing
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Fig. 224: Pressing On Tapered Roller Bearing Inner Race
Selecting correct locking collar for reverse gear wheel
Fig. 225: Allocation Of Operating Sleeve To Reverse Idler Gear

A Reverse gear wheel with Both types of locking collar can be

chamfered edge installed (with chamfered edge or
large shoulder).
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B Reverse gear wheel without Install only locking collar with

chamfered edge. large shoulder, do not use locking
collar with chamfered edge.
REVERSE IDLER GEAR, REMOVING AND INSTALLING
Reverse idler gear, removing and installing
Fig. 226: Reverse Idler Gear, Overview

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1 - Circlip
2 - Support plate
3 - Reverse idler gear
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 Different versions, assignment. See Selecting correct locking collar for reverse gear wheel
4 - Needle bearing
5 - Thrust washer
 With reverse idler gear shaft (arrow)

 It is not necessary to remove the reverse idler gear shaft to remove the reverse idler gear
 The reverse idler gear shaft is not available as a replacement part
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 To secure reverse idler gear shaft
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39 FINAL DRIVE, DIFFERENTIAL

FLANGE SHAFT OIL SEAL, REPLACING
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 2062 Driver
2:19:11 AM
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 T10037 Puller

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NOTE:  Removal procedure is identical for left and right seals.

 Exhaust system does not have to be removed.
Removing

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 Remove cover plates over right drive shaft (arrows 1 and 2).
 Unbolt drive shaft from flange on transmission:
 Tie up drive shaft as high as possible. Do not damage paint on drive shaft.
When replacing left oil seal:
Remove left flange shaft.
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When replacing right oil seal:
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Fig. 231: Removing Drive Flange (Right Side)

 Remove flange shaft, by screwing puller T10037 to transmission housing (arrow).
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 Always replace flange shaft circlip.
circlip -A-.
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Fig. 233: Flange Shaft Design

Assembling flange shaft with polygon bearing
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1 - Flange shaft
3 - Spacer ring
4 - Circlip
5 - Spacer ring - installed on shafts with 30 mm spline diameter
NOTE:  Rough running of the polygon bearings with flange shaft removed, does
not indicate bearings are defective. An acoustic test can only be
performed when installed.
 Inspect for signs of damage to polygon bearings (such as cracking in
outer race).
 A spacer ring -5- is installed between the polygon bearing and large
differential bevel gear on flange shafts with 30 mm spline diameter.
Installing
NOTE:  If used flange shaft is used, insert to a depth of 6.5 mm.

 Oil seal can also be driven in using drift 2062.
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Fig. 234: Installing Right-Hand Drive Flange Seal

 Keep seal straight when installing. Drive in new oil seal for right flange shaft to a depth of 5.5 mm below
outer surface of housing.
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 Fill space between sealing lip and dust lip with sealing grease G052 128 A1.
Fig. 235: Installing Left-Hand Drive Flange Seal

 Keep seal straight when installing. Drive in new oil seal for left flange shaft to a depth of 5.5 mm below
surface of cover.
 Bolt drive shaft to flange shaft.
 Install splash plates for drive shaft.
 Check oil level in manual transmission. Refer to Oil level in manual transmission, checking.
Tightening torques
Component Nm
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M10 70
Drive shaft heat shields 23
SPEEDOMETER SENSOR AND DRIVE WHEEL, REMOVING AND INSTALLING
Speedometer sensor and drive wheel, removing and installing
 Transmisison installed
Speedometer Vehicle Speed Sensor (VSS) -G22-, removing and installing
Removing
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Fig. 236: Identifying Speedometer Vehicle Speed Sensor (VSS) and O-ring
 Pull connector off sensor -A-.

 Press retaining clip down, turn sensor sideways and pull out upward.
Installing
 Replace O-ring -B- during installation.

 Insert sensor and click into place.
 Handle sensor carefully. If damaged it is possible that speedometer will not be accurate.
Speedometer drive wheel, removing and installing
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 VW 295 Mandrel
 VW 681 Release lever
 2062 Drift
 T10037 Puller

2:19:12 AM Page 8

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Removing

 Unbolt drive shaft from flange shaft.
 Place drip tray underneath.


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 Remove speedometer sensor. Refer to Speedometer Vehicle Speed Sensor (VSS) -G22-, removing and
installing.
 Remove speedometer drive wheel:
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Fig. 240: Press Drive Gear Retaining Clips In Direction Of Arrows Using Screwdriver
 With a screwdriver press retaining clips in direction of arrows.

 Remove drive wheel by prying out, alternating between sides.
Installing
NOTE: Install the drive wheel carefully onto the differential, make sure that it is kept
straight. Do not use excessive force - the drive wheel can break.
Installation position:
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Fig. 241: Identifying Installed Position Of Drive Gear, Retaining Clip And Seal
The drive peg of the drive wheel -A- faces seal -B- located in the groove of the differential.
The retaining clips (arrows) located in the annular groove in the differential.
 Always replace oil seal -B- and circlip -C-. Refer to Flange shaft oil seal, replacing.
 Check oil level and fill oil in transmission. Refer to Oil level in manual transmission, checking.
Tightening torques
Component Nm
M10 70
DIFFERENTIAL, REMOVING AND INSTALLING
Differential, removing and installing
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Fig. 242: Identifying Special Tools - Differential, Removing And Installing

 3257 Socket attachment SW 27
NOTE:  Removal and installation is possible with transmission installed.

 The differential can be removed and installed without removing selector
mechanism, input shaft, drive pinion and transmission cover. Removal of
the components above is necessary to adjust the differential.
 Inspect polygon bearings for visible damage.
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 Rough running of the polygon bearings with flange shaft removed, does not indicate that bearings are
defective. An acoustic test can only be performed installed.
 A spacer ring is installed between the polygon bearing and the large differential bevel gear on flange
shafts with 30 mm spline diameter. See Assembling flange shaft, -item 5-.
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Fig. 243: Differential, Removal And Installation, Overview
2 - Sealing ring
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 Replacing. Refer to Flange shaft oil seal, replacing
3 - Circlip
 Replace
 Removing and installing. See Removing and installing circlip
4 - Spacer ring
 Is only inserted on flange shafts with spline diameter of 30 mm.

 Removing. See Removing spacer ring
 Installing. See Installing spacer ring
5 - Flange shaft
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 Assembling flange shaft, Assembling flange shaft
6 - Differential with ring gear 1)
 Can be removed without removing gear cluster

can break using excessive force.
Removing and installing circlip
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circlip -A-.
Removing spacer ring
Fig. 245: Removing Spacer Ring

A - Internal puller 18.5... 23.5 mm, e.g. Kukko 21/3
 Pull out spacer ring using multi-purpose tool VW 771.
Installing spacer ring
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Fig. 246: Installing Spacer Ring

 Drive new spacer ring home, take care not to bend ring.
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Assembling flange shaft
Fig. 247: Flange Shaft Assembly, Overview

1 - Flange shaft
3 - Spacer ring
4 - Spacer ring - additionally installed on shafts with 30 mm spline diameter
5 - Circlip
NOTE: The needle bearings (polygon bearings) do not turn easily when the flange shaft
is removed. This does not indicate a bearing is faulty.
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DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
Differential, disassembling and assembling
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 VW 407 Press tool
 VW 408 A Press tool
 VW 447 H Thrust disk
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 VW 447 i Thrust disk
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 3138 Drift
 3144 Sleeve
 3296 Tube
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 VW 459 Installation and removal tool

 3 - Kukko 204/2 Puller
 4 - Kukko 22/2 Counter-support
 Kukko 44-2 Two-arm puller
NOTE:
2:19:12 AM Page 19
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Fig. 251: Differential, Disassembling And Assembling, Overview
 Removing and installing differential. Refer to Differential, removing and installing.

 Replace both tapered roller bearings.
2 - Shim "S2"
 Note thickness
3 - Outer race for right tapered roller bearing 1)
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 Pulling out. See Extracting tapered roller bearing outer race from transmission housing
 Pressing in. See Pressing tapered roller bearing outer race into transmission housing
4 - Inner race for right tapered roller bearing 1)
 Pulling off. See Pulling off inner race for right tapered roller bearing
 Pressing on. See Pressing on inner race for right tapered roller bearing
5 - Ring gear 1)
 Paired with drive pinion (final drive set)

 With a mandrel drive off housing. See Driving ring gear off housing
 Install to differential housing. See HEAT THE RING GEAR TO APPROX. 100 ° C and position
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6 - Differential housing 1)
 Allocation
7 - Bolt - 60 Nm + turn 45 ° further
 Always replace
 Lightly tighten bolts then tighten diagonally to specified torque.
8 - Inner race for left tapered roller bearing 1)
 Pulling off. See Pulling off inner race for left tapered roller bearing
 Allocation
can break using excessive force
10 - Outer race for left tapered roller bearing 1)
 Tapping out. See Driving out outer race for left tapered roller bearing out of cover
 Pressing in. See Driving outer race for left tapered roller bearing into cover
 Allocation
11 - Shim "S1"
2:19:12 AM Page 21
 Note thickness
13 - Large differential bevel gear
14 - Shaft for bevel gears
 Remove spring sleeve knocking out with drift
15 - Spring pin
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 For securing shaft for bevel gears
 With annular groove: Removing and installing. See Removing and installing spring sleeve
 Without annular groove: Drive out with mandrel
16 - Small differential bevel gear
17 - One-piece thrust washer
 When installing coat with transmission oil
Extracting tapered roller bearing outer race from transmission housing
Fig. 252: Pulling Outer Race/Tapered Roller Bearing Out Of Transmission Housing
A - Counter support, e.g. Kukko 22/2
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B - Internal puller 46...58 mm, e.g. Kukko 21/7
Pressing tapered roller bearing outer race into transmission housing
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 Install thrust pad VW 472/1 with taper in outer race.

 Support transmission directly beneath bearing support with VW 459/2.
Pulling off inner race for right tapered roller bearing
Fig. 254: Pulling Off Right Tapered Roller Bearing Inner Race
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A - Available two-arm puller, e.g. Kukko 44/2 or Kukko 20/10
A-.
Pressing on inner race for right tapered roller bearing
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Fig. 255: Pressing On Right Tapered Roller Bearing Inner Race
Pulling off inner race for left tapered roller bearing
Fig. 256: Pulling Off Left Tapered Roller Bearing Inner Race
A - Two arm puller, e.g. Kukko 204/2
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A-.
Installing inner race for left tapered roller bearing
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Fig. 257: Installing Left Tapered Roller Bearing Inner Race
WARNING: Attention:
Wear protective gloves.
Driving out outer race for left tapered roller bearing out of cover
Fig. 258: Driving Out Outer Race Of Left Tapered Roller Bearing From Cover
 Turn webs -A- and -B- out until they sit on outer race within recess in transmission.
Driving outer race for left tapered roller bearing into cover
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 Use thrust piece 2050 to press outer race for left tapered roller bearing into cover.
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 Install thrust piece 2050 with taper in outer race.
Driving ring gear off housing
Fig. 260: Driving Out Ring Gear From Housing

Heat the ring gear to approx. 100 ° C and position
2:19:12 AM Page 26
Fig. 261: Installing Ring Gear

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 Install ring gear guide on centering pins -A- (locally made).
 Allow ring gear to cool off slightly before inserting bolts. Then tighten to specified torque.
Installing bevel gears
Fig. 262: Installing Small Differential Bevel Gears

 Lubricate one-piece thrust washer with transmission oil and install.

 Insert large differential bevel gears.
 Insert small differential bevel gears at 180 ° from their final position and rotate into place -arrow-.
 Drive in differential bevel gear shaft into final position and secure.
Removing and installing spring sleeve
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Fig. 263: Pulling Out Spring Pin With Side Cutting Pliers
Removing
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 Using side-cutting pliers pull out spring sleeve with annular groove.
 Using a mandrel drive out from behind the spring sleeve without annular groove.
Installing
 Drive in spring sleeve to stop.
DRIVE PINION AND RING GEAR, ADJUSTING
Drive pinion and ring gear, adjusting
NOTE:  Carefully adjust the drive pinion and ring gear for the service life and
smooth running of the final drive. For this reason, the drive pinion and ring
gear are matched together during manufacturing, and checked to make
sure a good mesh pattern and quiet running. The position of quietest
running is found by moving the drive pinion in an axial direction and at the
same time lifting the ring gear out of the zero-play mesh position by
maintaining the backlash within the specified tolerance.
 The deviation "r" based on master gauge "Ro" is measured and marked on
the outer circumference of the ring gear. Final drive set (drive pinion and
ring gear) may only be replaced together!
Adjusting final drive sets; identification
2:19:12 AM Page 28
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Fig. 264: Identifying Gear Set Markings And Adjustment Dimensions
1 - "0937" indicates Oerlikon final drive set with a ratio of 37 : 9.
2 - Pairing number (312) of final drive set
3 - Deviation (tolerance) "r" based on the test machine master gauge used in production. The deviation
"r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm
Ro - Length of test machine master gauge used.
2:19:12 AM Page 29
R - Actual dimension between ring gear and face of drive pinion at point with quietest running for this
gear set
Vo - Hypoid offset
Shims position
Fig. 265: Identifying Shim Locations

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NOTE: Adjustment overview when replacing individual components of transmission. .
S1 - Shim for ring gear in cover for final drive
S2 - Shim for ring gear in transmission housing
2:19:12 AM Page 30
S3 - Shim for drive pinion in transmission housing
S4 - Shim for drive pinion in transmission cover
Adjustment overview
NOTE: If repairs have been carried out on the transmission adjust drive pinion, ring
gear or final drive set if components have been replaced which directly effect
the adjustments of the final drive. Refer to following table to avoid unnecessary
adjustments:
To be adjusted:
Ring gear Drive pinion Drive pinion Backlash
Parts replaced: "S1"+"S2" 1) "S3"+"S4" 1) "S4" 1) Refer to Measuring
? Refer to Ring gear, using deviation "r" Refer to Re- backlash
adjusting Refer to Drive determining "S4"
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pinion, adjusting shim when
installing new
transmission cover
Transmission X X X
housing 3)
Transmission cover X
Differential housing X X
tapered roller X X
bearings for drive
pinion
tapered roller X X
bearing for
differential
Final drive set 2) X X X
Cover for final drive X X
1) Shims; installation position.
2) Drive pinion and ring gear; only replace together
3) If the transmission housing is replaced the input shaft also needs to be adjusted. Refer to Input shaft,
adjusting, adjusting input shaft.
Final drive set sequence for re-adjusting
2:19:12 AM Page 31
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Fig. 266: Drive Pinion And Gear Ring Adjusting Sequence
When ring gear and drive pinion have to be adjusted, in the interests of a rational sequence, keep to the
following order:

differential). Refer to Determining total shim
thickness "Stotal" for shims "S1" + "S2" onward.
drive pinion). Refer to Determining total shim
thickness "Stotal" for shims "S3" + "S4"
"S4" so that the distance from center of ring gear to
face of drive pinion is the same as distance "R"
which was determined during production. Refer to
"S2" so that specified backlash exists between ring
gear and drive pinion. Refer to Determining
thickness of shim "S2"
NOTE: Overview of components and shims.
Drive pinion, adjusting
2:19:12 AM Page 32
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 Crankshaft seal installing tool VW 204 B Crankshaft seal installing tool

 VW 296 Oil seal extractor
 VW 385 Universal measuring tool

2:19:12 AM Page 33
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 VW 519 Tube
 3128 Puller

Re-adjustment of the drive pinion is only necessary if the final drive set, tapered roller bearing for drive pinion
or transmission housing is replaced. .
The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test
machine in production. Maximum care and cleanliness are essential when performing repairs and taking
2:19:12 AM Page 34
measurements for achieving good results.
(adjusting pre-load of tapered roller bearing for drive pinion)
 Differential removed.
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 Without shims press large tapered roller bearing outer race into transmission housing.
 Insert rubber disc-item 40 and pressure plate-item 39 into transmission cover. Refer to Drive pinion,
disassembling and assembling
 Press small tapered roller bearing outer race together with a 1.00 mm thick preliminary shim S4* into
transmission cover.
NOTE: A shim "S4" with a thickness of 1.0 mm is installed for initial measurements. It
is referred to as "S4*" in the following. After determining measurement "e",
2:19:12 AM Page 35
"S4*" will be replaced by the correct shim "S4".
 Pressing on inner race for tapered roller bearing. Refer to Drive pinion, disassembling and assembling.
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Fig. 271: Identifying Lower Tapered Roller Bearing
 Secure lower tapered roller bearing (arrow). See Determining thickness of circlip
NOTE: Illustration shows drive pinion without gear wheels.

 Turn transmission so that transmission cover is downward.
Fig. 272: Pressing Down On Drive Pinion Head Using Removal Tool VW 296
 Press down on face of drive pinion head with lever VW 296 until the tapered roller bearing outer race
contacts the transmission cover.
 Continue pressing on face of drive pinion head, at the same time turn drive pinion 8 turns by hand, so
tapered roller bearing can settle.
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Fig. 273: Installing Dial Gauge (3 Mm Range) And Set To "0" With 2 Mm Pre-Load
 Install dial gauge (3 mm measuring range) and set to "0" with 2 mm pre-load.
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NOTE:  Use dial gauge extension 30 mm long.
 The dial gauge extension must contact the machined surface on the face
of pinion.
 Turn transmission 180 ° so that the transmission cover is upward.

 Read play on dial gauge and note reading.
 Measurement in example: 0.45 mm
NOTE: If the measurement has to be repeated, drive pinion must first be rotated
another5 turns in each direction to settle the tapered roller bearing. Reset dial
gauge to "0" with 2 mm pre-load.
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Formula: =
pre-load
Example:
+ Measurement (example) 0.45 mm
"S3" + "S4"
Determining thickness of preliminary shim S3*
Formula: =
"S3*" "Stotal" - "S4*"
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Example:
"S3" + "S4"
- Inserted shim "S4*" 1.00 mm
 Extract large tapered roller bearing outer race. See Pulling out outer race for large tapered roller
bearing..
 Insert preliminary shim S3* into transmission housing and re-install outer race. See Pressing in outer
race for large tapered roller bearing..
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 Rotate drive pinion 5 turns in both directions to settle tapered roller bearing.
NOTE:  If drive pinion cannot be turned by hand, insert a bolt M10 x 20 in drive
pinion head and turn pinion by using a tool on this bolt.
 Remove bolt again.
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load.
 If correct shims have been selected dial gauge will now indicate following value:
 0.05... 0.15 mm

 Secure bolt M10 x 20 on drive pinion head and turn drive pinion 8 turns to allow tapered roller bearing to
settle.
 Remove bolt.
Determining dimension "e"
NOTE: Measurement "e" is required to determine the final shim thickness of "S3" and
"S4".
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Fig. 277: Setting Adjusting Rings Of Measuring Bar VW 385/1

 Set adjustment rings of universal mandrel VW 385/1 to following measurements:
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 Dimension b = 75 mm
Fig. 278: Assembling Measuring Bar VW 385/1

 Assemble universal mandrel VW 385/1 according to illustration.
Dial gauge extension A Ro Ring gear diameter

6.5 mm 54.95 170 mm
9.3 mm 59.65 180 mm
 Set master gauge VW 385/30 to Ro according to ring gear diameter and install onto mandrel.
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Fig. 279: Placing End Gauge On Drive Pinion Face

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 Place end measuring plate on face of drive pinion head.
NOTE: Make sure plate contact surface fits exactly and is free of oil.
Fig. 280: Inserting Measuring Mandrel VW 385/1 Into Housing

 Remove master gauge and insert measuring mandrel in housing.
 With Ro = 54.95 mm, a dial gauge extension = 6.5 mm length must be screwed in instead of dial gauge
extension VW 385/15.
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 The dial gauge faces cover for final drive
 Install cover for final drive and tighten 4 bolts to 22 Nm.

 Using sliding setting ring to pull 2nd centering disc outward until mandrel can still be turned by hand.
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Fig. 281: Turning Measuring Mandrel Until Dial Gauge Plunger Tip Touches End Gauge On Pinion
Shaft Head And Measure Maximum Runout
 Turn mandrel until the dial gauge point touches the end measuring plate on drive pinion head, then
measure maximum deflection (return point).
 Measurement in following example: "e" = 0.26 mm (in red scale on dial)
NOTE: After removing universal mandrel check again that the dial gauge, with master
gauge VW 385/30 in place, indicates "0" with 2 mm pre-load.
 If dial gauge reading is in red scale, subtract dimension "e".

 If dial gauge reading is in black scale, add dimension "e".
 The deviation "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied
as replacement parts and marked on the outer circumference of the ring gear.
Formula:
"S3" = "S3*" + "r" + "e"
("e" in black scale)
"S3" = "S3*" + "r" - "e"
("e" in red scale)
Example:
2:19:12 AM Page 42
+ Deviation "r" 0.38 mm

- Determined value "e" (red scale) 0.26 mm

0.40 0.55 0.70
0.45 0.60 0.75
0.50 0.65
necessary.
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Formula:
"S4" = "Stotal" - "S3"
Example:
Total shim thickness "Stotal" 1.60 mm

Shim thickness S3 - 0.72 mm
Shim thickness S4 = 0.88 mm

0.49 0.69 0.85
0.57 0.73 0.89
0.61 0.77 0.97
0.65 0.81
necessary.
Checking dimension "r"
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 Install drive pinion with determined shims "S3" and "S4" and turn 5 turns in both directions.
Fig. 282: Insert Universal Mandrel And Perform Check Measurement

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 Insert universal mandrel "Determining measurement `e'". Refer to Determining dimension "e", and
perform check measurement.
 Read off dial gauge counterclockwise (red scale).
 If the shims have been correctly selected, the deviation "r" (marked on outer circumference of ring gear)
must be shown within a tolerance of ± 0.04 mm.
Re-determining "S4" shim when installing new transmission cover
Fig. 283: Identifying Dial Gauge Holder VW 387

2:19:12 AM Page 44
Fig. 284: Installation Arbor VW 792

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 Dial gauge
 Dial gauge extension
 Use depth gauge to within at least 5/100 mm.

 Clean housing flange.
Fig. 285: Measuring Difference In Depth On Old And New Transmission Cover
 Measure difference in depth "a" on old and new transmission cover.
Example:
2:19:12 AM Page 45
Depth "a" on old transmission 257.40 mm

cover
Depth "a" on new transmission 257.55 mm
cover
= Difference 0.15 mm
 Install thicker shim "S4" if new transmission cover is deeper.

 Install thinner shim "S4" if the old transmission cover is deeper.
Example:
Previous shim "S4" 0.95 mm

+ Difference 0.15 mm
= New "S4" shim 1.10 mm
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Available shims. Refer to table under The following shims are available for "S4".
 Install outer race for tapered roller bearing with shim "S4" in transmission cover. See Pressing in outer
race for small tapered roller bearing
 Insert completely assembled drive pinion in transmission housing again.
NOTE: Drive pinion can be rotated by simultaneously turning both flange shafts.
2:19:12 AM Page 46
load.
If the correct shims have been selected the dial gauge will now indicate the following value:
 0.05... 0.15 mm

Ring gear, adjusting
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2:19:13 AM Page 47
(Adjusting differential)
 VW 385/17 End measuring plate

 VW 388 Measuring lever
 VW 521 Adjustment tool
 3177 Clamp
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2:19:13 AM Page 48
 VW 382/10 Dial gauge extension

 VW 459/2 Installing and removing tool

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(adjusting pre-load of tapered roller bearing for differential)
 Drive pinion removed
 Pull out flange shaft oil seal with oil seal extractor VW 681.
 Remove tapered roller bearing outer race for differential and remove shims. Refer to Differential,
disassembling and assembling.
2:19:13 AM Page 49
 Drive outer race for small tapered roller bearing with shim "S2" into transmission housing. For
measurement purposes use a 1.20 mm thick "S2*" shim (2 shims of 0.60 mm).
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NOTE: For measurement purposes a shim "S2" with a thickness of 1.20 mm is initially
inserted. It is referred to as "S2*" in the following. After determining the
backlash "S2*" will be replaced by the correct "S2".
 Press outer race for tapered roller bearing without shim "S1" into cover for differential.
 Insert differential without drive wheel for speedometer sensor -G22- into transmission housing.
 Install cover for differential with 4 bolts (25 Nm).
 Position transmission so that cover for differential faces up.
 Turn differential 5 turns in both directions to settle the tapered roller bearing.
 Place measuring plate VW 385/17 onto differential.
2:19:13 AM Page 50
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Fig. 292: Installing Magnetic Plate 50Mm Dia. VW 385/17 And Dial Gauge
 Assemble measuring equipment, use a 30 mm dial gauge extension.

NOTE: The tip of the dial gauge must be positioned on center of differential.
 Lift differential without turning; read play on dial gauge and note.
 Measurement in following example: 0.62 mm
NOTE:
Fig. 293: Securing Special Tools VW 521/4 And VW 521/12 At Right On

Differential (Housing Side)
2:19:13 AM Page 51
If measurement has to be repeated, differential must again be turned 5 turns in

each direction to settle the tapered roller bearing.
Formula: =
pre-load
Example:
Inserted shim(s) "S2*" 1.20 mm
+ Measurement 0.62 mm
"S1" + "S2"
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Determining thickness of shim "S1*"
NOTE:  The preliminary adjustment shim "S1*" will be replaced with the final shim
"S1" after determining the backlash.
 The total shim thickness "Stotal" remains the same.
Formula:
"S1*" = "Stotal" - "S2*"
Example:
"S1" + "S2"
- Inserted shim(s) "S2*" 1.20 mm
Measuring backlash
 Drive pinion and shims "S3*" and "S4*" installed
 Installing differential with ring gear: S1* is installed on cover side, S2* in transmission housing.
 Install final drive cover and tighten bolts to 25 Nm.
 Turn differential 5 turns in both directions so that the tapered roller bearings settle.
2:19:13 AM Page 52
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 Secure dial gauge holder VW 387 on housing.

 Install dial gauge with dial gauge extension VW 382/10 (6 mm flat).
 Set measuring lever VW 388 to dimension "a":
Dimension "a" Ring gear diameter

67 mm 170 mm
72 mm 180 mm
 Measure play between teeth flanks (backlash) as follows:

 Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
 Set dial gauge to "0" with 2 mm pre-load.
 Turn ring gear back until lying against an opposite tooth flank (backlash).
 Read backlash and note value.

 Turn ring gear 90 ° and repeat measurements another 3 times.
NOTE:
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Fig. 295: Installing Clamp 3177 "A"

 If drive pinion rotates when the differential is turned, install bracket VW 3177 -A- so that backlash can be
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measured exactly.
 Loosen the clamp in order to turn the ring gear.
 Cut-out for large differential bevel gears must point toward drive pinion when differential is inserted.
 With holder 3177 inserted, install differential offset by 180 ° and repeat measurement.
Determining average backlash
 Add four measured values together and divide by four.
Example:
1st measured value 0.28 mm
+ 2nd Measured value 0.30 mm
+ 3rd Measured value 0.30 mm
+ 4th Measured value 0.28 mm
= Sum of measured values 1.16 mm
 Result: The average backlash is 1.16 mm divided by 4 = 0.29 mm
NOTE: If the individual measurements differ by more than 0.06 mm this means that the
installation of the ring gear is not correct or that the final drive set itself is
defective. Check installation, replace final drive set if necessary.
Formula: =
"S2" "S2*" - backlash + lift
Example:
2:19:13 AM Page 54

- Average backlash 0.29 mm
+ Lift (constant) 0.15 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
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necessary.
Formula: =
"S1" "Stotal" - "S2"
Example:
"S1" + "S2"
- Thickness of shim "S2" 1.06 mm

0.45 0.65 0.85
0.50 0.70 0.90
0.55 0.75
0.60 0.80
necessary.
2:19:13 AM Page 55
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 After installing shims "S1" and "S2", turn differential 5 turns in both directions so that tapered roller
bearings settle.
 Measure backlash four times on circumference.
 Specification: 0.12... 0.22 mm
NOTE:  If the backlash is beyond the tolerance, the adjustments must be repeated.
The total shim thickness "Stotal" must not be changed when the
adjustment is repeated.
 The individual measurements must not differ by more than 0.06 mm from
each other.
2:19:13 AM Page 56

5 Spd. Manual Transmission 012 and 01W Front Wheel Drive

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5 Spd. Manual Transmission 012 and 01W Front Wheel Drive

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What are the main components of the manual transmission?

What are the main components of the manual transmission?

How are the transmission ratios calculated?

How are the transmission ratios calculated?

2005 Audi A4 Quattro

TRANSMISSION 5 Spd. Manual Transmission 012/01W Front Wheel Drive

5 Spd. Manual Transmission 012/01W Front Wheel Drive

00 GENERAL, TECHNICAL DATA

Code letters and date of manufacture (arrow 1)

Manual transmission 012 / 01W (arrow 2)

Fig. 2: Manual Transmission 012/01W/0A9

Manual transmission 012 / 01W (arrow 2)

Fig. 3: Code Letters And Date Of Manufacture

Code letters and date of manufacture (arrow 1)

Additional data are production-related

Code letters, application, ratios, capacities

Manual transmission 5-speed 012 / 01W

Code letters ENN FPS

1) Drive axle with triple rotor joint.

Fig. 4: Power Transfer, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

5 - Drive pinion (output shaft)

NOTE: Arrows face in direction of travel.

Calculating transmission ratios "i"

Transmission ratio = No. of teeth on : No. of teeth on drive

General repair instructions

For a complete list of special tools used in this article

Refer to Booklet; Special tools, Workshop equipment

 Thoroughly clean housing joint surfaces before applying sealing paste.

O-rings, seals, gaskets

 Always replace O-rings, seals and gaskets.

 Do not over-stretch circlips.

 Always replace self-locking nuts and bolts.

Gears, synchro-hubs, inner races for sliding gears

Clutch mechanism, servicing

Fig. 7: Clutch Mechanism, Servicing - Pedal Cluster And Hydraulic System

II - Exploded view of hydraulic system. Refer to Hydraulic system, assembly overview

NOTE:  Note or obtain radio code on vehicles with coded radio.

 Lubricate all bearings and contact surfaces with polycarbamide grease G

CAUTION: On vehicles equipped with Audi Telematics by OnStar ® , switch-off the

Pedal cluster, assembly overview

 Removing and installing. Refer to Slave cylinder, removing and installing

2 - Fulcrum pin for clutch and brake pedal

4 - Hex socket-head bolt - 25 Nm

 Mounting is maintenance-free, do not grease

6 - Clutch pedal switch

 Can only be installed one time

7 - Hex socket-head bolt - 5 Nm

 For securing pivot pins for clutch and brake pedal

 Removing and installing. Refer to Slave cylinder, removing and installing

11 - Hex socket-head bolt - 20 Nm

 Removing and installing. Refer to Slave cylinder, removing and installing

 Black end points toward clutch pedal

Refer to Parts list

14 - Clutch Pedal Position (CPP) Switch -F194-

 Can only be installed one time

 For securing brake master cylinder/brake servo to mounting bracket

Over-center spring, removing and installing

Special tools and workshop equipment required

Fig. 9: T40025 Installation Clamp