Page 9 of 14
00-19
Bearings
Install needle bearings with the lettering on the
bearing (the side with thicker metal) facing the
drift or other installation tool.
Grease needle bearing for the input shaft in the
crankshaft.
Lubricate all bearings in transmission with gear
oil before installing.
Always replace tapered roller bearings on one
shaft together and use new bearings from the
same manufacturer.
Heat tapered roller bearing inner races to
approx. 100 C (212 F) before installing. Press
in until stop is reached so there is no axial play.
Do not interchange inner and outer bearing
races with those from other bearings of the
same size.
The tapered roller bearings for the output shaft
and the differential in the transmission are low-
friction bearings. Do not additionally oil new
tapered roller bearings when measuring friction
torque. The bearings are pre-treated at the
Pa
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Page 10 of 14
factory with a special type of oil for this
purpose.
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Page 11 of 14
00-20
Shims
Use a micrometer to measure the shims at
several points. Different tolerances make it
possible to obtain the exact shim thickness
required.
Check for burrs and signs of damage.
Only install shims that are in perfect
condition.
Gears, synchro-hubs, inner races for sliding
gears
Heat gears and synchro-hubs to approx. 100
C (212 F) before installing. Press in until stop
is reached so there is no axial play.
Heat inner races for sliding gears to approx.
100 C (212 F) when installing.
The temperature can be checked using
VAG1558 temperature tester.
Observe installation position.
Sliding gears
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Page 12 of 14
After assembling, check axial play of 1st to 5th
sliding gears and reverse sliding gear (0.15-0.35
mm .006-.014 in.) and check for free movement.
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Page 13 of 14
00-21
Synchronizer rings
Do not interchange.
When re-using, install synchronizer rings with
the same gear with which they were previously
matched.
Check for signs of wear; replace if necessary.
Lubricate with gear oil before installing.
Clutch mechanism
When removing transmission, remove clutch
slave cylinder without opening hydraulic lines.
CAUTION!
Do not depress the clutch pedal after
removing the slave cylinder. Otherwise the
piston will be pressed out of the slave
cylinder.
Do not cant clutch pressure plate, loosen and
tighten in a diagonal sequence and in stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the bellhousing, flywheel and
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Page 14 of 14
the side of the engine facing the transmission.
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