AWD Vehicles

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-- Remove the circlip -arrow-.

-- Remove the bearing inner race -Item 25- or -Item 30- -arrow- using the Two-Arm Puller (Kukko 20/10) :VAS 251 001 and Seal Installer - Shaft Seal :T10431/1 .

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Vehicles without self-locking center differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the Extracting Tool - Adapters :T40413/7 -1-.

-- Bolt the Extracting Tool - Adapter :T40413/7 with the Gearbox Assembly Tool :T40213A .

-- Tighten the Gearbox Assembly Tool :T40213A in the vise or on the Gearbox Support :T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The gear set is secured with the Retaining Strap :T40155 and Engine/Gearbox Support Shackle (2 pc.) :10-222A/12 on the Workshop Crane :VAS 6100 .
The bolts from the Extracting Tool - Adapter :T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter :T40413/7

4 - Gearbox Assembly Tool :T40213A

5 - Extracting Tool - Adapter :T40413/8

6 - Extracting Tool - Nut :T40213/3

-- Switch the Gearshift Rail/Shift Fork for 4th and 6th Gear -1-, Gearshift Rail/Shift Fork for 5th and 7th Gear -2- and Gearshift Rail/Shift Fork for 1st and 3rd Gear -3- in the -direction of the arrows-.

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-- Warm the bolt -arrow- to approximately 100 °C (212 °F).

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Tip:

The bolt from the output shaft has a very high loosening torque.

-- Remove the bolt -arrow- with the Socket - Xzn 18mm :T10162A -1-.

If when warning the bolt the oil pipe -2- in the output shaft is damaged it must be replaced.

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-- Drive out the oil pipe -2- using the Valve Guide/Clutch Release Push Rod Seal Drift :10-206 -1- from the output shaft in the -direction of the arrow-.

-- Drive in the new oil pipe on the opposite side again.

-- Then shift all gears into the transmission neutral position.

Continuation for all vehicles

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-- Remove the bolt -arrow- and remove the shift forks for 4/6 gear and 5/7 gear together.

-- Remove the input shaft 1 from the gear set.

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CAUTION:

Damage to input shaft 1

When removing the input shaft 1, the 7th gear wheel may already be loosened and can fall.

-- Shift fork the gearshift rail/shift fork for 1st and 3rd gear -1- and gearshift rail/shift fork for 2nd gear and reverse gear -2- upward in the -direction of the arrow-.

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Vehicles with self-locking center differential

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-- Remove the circlip -1- from the outer output shaft -2-.

Screw in the Thrust Piece :T10205/13 in the Hydraulic Cylinder :VAS 6178 .

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Press on the 4th gear 1, vehicles with self-locking center differential

Fig 1: Press on the 4th Gear -1-, Vehicles with Self-Locking Center Differential

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2 - Press Piece - Multiple Use :30-11

3 - Press Piece - 31.5mm :VW418A

4 - Extracting Tool - Screwdriver Bit :T40413/2

5 - Hydraulic Press :VAS 6178

6 - Extracting Tool - Puller :T40413/1

Vehicles without self-locking center differential

Drive Wheel for spur gear unit 1 and drive wheel roller bearing inner race 2.

Fig 2: Drive Wheel for Spur Gear -1- and Drive Wheel Roller Bearing Inner Race -2-

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3 - Press Piece - Multiple Use :VW426

4 - Extracting Tool - Screwdriver Bit :T40413/2

5 - Extracting Tool - Puller :T40413/1

6 - Hydraulic Press :VAS 6178

-- Remove the spacer sleeve -Item 4-.

Press on the 4th gear 1, vehicles without self-locking center differential

Fig 3: Press on the 4th Gear -1-, vehicles without Self-Locking Center Differential

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2 - Extracting Tool - Screwdriver Bit :T40413/2

3 - Hydraulic Press :VAS 6178

4 - Extracting Tool - Puller :T40413/1

Continuation for all vehicles

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-- Remove the circlip -2- for the drive axle 2 -1-.

Align the drive axle 2 1

Fig 4: Align the Drive Axle 2 -1-

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CAUTION:

Risk of destroying the gears, shaft and bearing bracket.

To press out the input shaft 2, align as follows.
The bevel -arrow- of the drive axle 2 -1- must be located on the side of the intermediate sprocket for the reverse gear -2-.

Press out the drive axle 2 1, vehicles without self-locking center differential

Fig 5: Press Out the Drive Axle 2 -1-, Vehicles without Self-Locking Center Differential

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2 - Bearing Installer - Multiple Use :32-111

3 - Press Piece - Rod :VW407

4 - Bearing Installer - Bearing Press Plate :T10084A

5 - Press Plate :VW401

6 - Press Plate :VW402

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate :T10084A -arrow-.

Press out the drive axle 2 1, vehicles with self-locking center differential

Fig 6: Press Out the Drive Axle 2 -1-, Vehicles with Self-Locking Center Differential

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2 - Press Piece - Multiple Use :40-105

3 - Press Piece - Rod :VW408A

4 - Press Piece - Multiple Use :VW519

5 - Exhaust Pipe Wedge Set :3140A/1

6 - Press Plate :VW402

7 - Press Plate :VW401

8 - Bearing Installer - Bearing Press Plate :T10084A

To press on the drive axle 2 have a second technician help.
The bearing bracket must be positioned on the Bearing Installer - Bearing Press Plate :T10084A -arrow-.

Continuation for all vehicles

Depending on the servicing in the next work procedure:

Input Shaft 2, Disassembling and Assembling. Refer to INPUT SHAFT 2, DISASSEMBLING AND ASSEMBLING .
Input Shaft 1, Disassembling and Assembling. Refer to INPUT SHAFT 1, DISASSEMBLING AND ASSEMBLING .
Output Shaft, Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .
Vehicles with self-locking center differential: inner output shaft disassembling and assembling. Refer to INNER OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING, ONLY VEHICLES WITH SELF-LOCKING CENTER DIFFERENTIAL .

Assembling

Insert the input shaft 2 2 in the bearing bracket

Fig 7: Insert the Input Shaft 2 -2- in the Bearing Bracket

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Warm up the output shaft bearing -1- using the Hot Air Blower.
The bevel -arrow- of the output shaft 2 must be located on the side of the intermediate sprocket for the reverse gear -3-.

Press in the input shaft 2 2 in the bearing bracket 3

Fig 8: Press in the input shaft 2 -2- in the Bearing Bracket -3-

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When pressing in the input shaft 2 pay attention to the splines -arrows-.

1 - Press Piece - Multiple Use :VW412

4 - Extracting Tool - Sleeve :T40413/10

-- Determine and insert the thickest circlip -2- that can still be inserted for the drive axle 2 -1-.

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The following circlips are available. Refer to the => Parts Information for the part number.

Circlip thickness (mm)
2.41	2.49	2.57
2.45	2.53

4th Gear 1, Installing

Fig 9: 4th Gear -1-, Installing

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3 - Bearing Installer - Differential Bearing :40-21

Warm the 4th gear -1- using the Inductive Heater :VAS 6414 to 120 °C (248 °F).
When pressing on the splines -arrow- pay attention to the 4th gear -1- and the gear assembly for the 4th gear -2-.
Vehicles with self-locking center differential: insert the circlip -Item 9-

Vehicles without self-locking center differential

Drive wheel for spur gear unit 2, pressing on

Fig 10: Drive Wheel for Spur Gear -2-, Pressing on

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3 - Bearing Installer - Differential Bearing :40-21

Position the spacer sleeve -1- beforehand.
Warm the drive wheel for spur gear unit -2- to 120 °C (248 °F) using the Inductive Heater :VAS 6414 .
The groove on the drive wheel of the spur gear unit points to the Bearing Installer - Differential Bearing :40-21 .

Press on the output shaft roller bearing inner race 1

Fig 11: Press on the Output Shaft Roller Bearing Inner Race -1-

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2 - Press Piece - Trailing Arm :2010

Warm the output shaft roller bearing inner race -1- using the Inductive Heater :VAS 6414 to 120 °C (248 °F).
Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Trailing Arm :2010 -2-.

Continuation for all vehicles

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-- Carefully guide the input shaft 1 into the gear set -arrow-. While doing so, make sure the needle bearings -A and B- are installed correctly.

-- Position the shift forks and secure with the bolt -arrow-.

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The following procedure is only necessary after disassembling the output shaft.

-- Press in the locking sleeve for the gearshift rail/shift fork 1st and 3rd gear -A- and the locking sleeve for the gearshift rail/shift fork 2nd and reverse gear -B-. Refer to Figure.

Fig 12: Press in the New Retaining Sleeves -A, B, C and D-

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Vehicles without self-locking center differential

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-- Install the four bolts (M8 x 30) -2- in the threaded holes marked with "C" from the Extracting Tool - Adapters :T40413/7 -1-.

-- Bolt the Extracting Tool - Adapter :T40413/7 with the Gearbox Assembly Tool :T40213A .

-- Tighten the Gearbox Assembly Tool :T40213A in the vise or on the Gearbox Support :T40206 .

-- Insert the gear set -1- in the Assembly Tool.

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The bolts from the Extracting Tool - Adapter :T40413/7 -3- must engage in the holes in the gear assembly from the 7th gear -2-.

3 - Extracting Tool - Adapter :T40413/7

4 - Gearbox Assembly Tool :T40213A

5 - Extracting Tool - Adapter :T40413/8

6 - Extracting Tool - Nut :T40213/3

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-- Clean the internal threads of the output shaft with a thread tap.

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-- Install the new bolt -arrow- using the Socket - Xzn 18mm :T10162A -1- and tighten.

-- Then shift all gears into the transmission neutral position.

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-- Warm the bearing inner race -Item 25- or -Item 30- with a Inductive Heater :VAS 6414 and push with the shoulder downward -arrow A- all the way.

-- Install the circlip -arrow-.

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-- Install the oil pan -Item 5-.

-- Install the gear set. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

Tightening Specifications