Page 9 of 12
00-16
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 damage.
Only install perfect, undamaged shims.
Gears, synchro-hubs, inner races for sliding
gears
Heat gears and synchro-hubs to approx. 100
C before installing. Press in onto stop when
installing so there is no axial clearance.
Heat inner races for sliding gears to approx.
100 C when installing.
The temperature can be checked with
Temperature tester V.A.G 1558.
Observe installation position.
Sliding gears
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pair instructions
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Page 10 of 12
After installing, check 1st to 6th speed sliding
gears for axial clearance of 0.15-0.35 mm and
check that they rotate freely.
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pair instructions
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Page 11 of 12
00-17
Synchronizer rings
Do not interchange synchronizer rings. When
reusing always fit to the same gear.
Check for wear, replace if necessary.
Lubricate with gear oil before installing.
Clutch mechanism
When removing transmission, remove clutch
slave cylinder without disconnecting lines.
If the slave cylinder is removed with the
hydraulic line attached, do not depress clutch
pedal. Otherwise the piston will be pressed out
of the slave cylinder.
Ensure that the pressure plate is kept straight:
loosen and tighten bolts in a diagonal sequence
and in several gradual stages.
To reduce odor caused by a burnt clutch,
thoroughly clean the clutch bellhousing, the
flywheel and the parts of the engine facing the
transmission.
Pa
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pair instructions
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Page 12 of 12
Vehicles with V6 2.7 ltr bi-turbo engine have an
SAC pressure plate. On these vehicles an
adjuster ring has to be reset ( Page 30
-42
)
when replacing the clutch plate on its own.
Pa
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pair instructions
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