Gearbox removal & installation: Installation — VW

🧭 Before you start

Fits: platform codes 5W9, 5X9, 5X1, 5W1, 5X5, 5W5

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

Don't miss

• In the event the values don't match, increase or reduce the number of screw thread that appear between the housing and the inversion lever (A)
• The backing washer must have its external groove directed towards the housing.After 26/04/2004 the back washers of 5th gear are symmetrical and have no particular side for assembly

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 34 workshop diagrams for AGR

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Install the bushings and the springs in the correct positions of the new housing with a Pressure pinVW 411 and a Pressure base VW 433.
2. Install the external ring of the rear bearing on the pinion shaft with an Pressure pinVW 407 and a Pressure baseVW 433.
3. Adjust the pinion.
4. Remove the gearbox housing from the differential housing.
5. Install the circlip with nose pliers.

6. Install the intermediate roller bearing on the primary shaft with a Pressure pinVW 408A and a Pressure baseVW 447H.
7. Install the retaining ring of the rear bearing and tighten the screws with 25 Nm. — 25 Nm (18 lb-ft)
8. Install the selector fork lever bushing with a Pressure pinVW 411 and a Extractor and fitterVW 222A.
9. Install the sliding rod of 5th and reverse gears.
10. Install the reverse gear cog and axel, and then the inversion lever.
11. Install the washer and the fastening screw (without tightening it) of the reverse gear inversion lever.
12. Position the reverse gear inversion lever so that 3 or 4 lines of thread of the screw appear between the housing and the inversion lever, distance (A).
13. With a caliper, measure the distance (B) between the inversion lever and the rod. B = 0.30 to 1.80 mm [Note: In the event the values don't match, increase or reduce the number of screw thread that appear between the housing and the inversion lever (A)]
14. Tighten the fastening screw of the reverse gear inversion lever with 35 Nm of torque and test the smoothness of operation in all positions, with an "Adaptor for bits 5/16" (enc. 1/2")" or VAG 1603AVW 002P and a TORX - TX 50 Splined bits or VAG 1603AVW 002L. — 35 Nm (26 lb-ft)
15. Install the reverse gear retainer and tighten with 35 Nm. — 35 Nm (26 lb-ft)
16. Remove the sliding cog from the reverse gear and the axel.
17. Position the sliding rod of the 1st and 2nd gears with the selector fork and pinion shaft in the gearbox housing.
18. Install the sliding cog of the reverse gear and the axel.
19. Install the primary shaft with the selector fork of 3rd and 4th gears and the external rear bearing of the pinion shaft in the gearbox housing with the following tools: Pressure diskVW 412, Pressure tubeVW 426 and PlateVW 402.
20. Install the sliding rid of the 3rd and 4th gears and the selector fork, securing it with the locking pin.
21. Heat the 5th gear cog of the pinion shaft, the internal ring of the needle bearing of 5th gear and the synchronizer body to 120°C.
22. Install the backing washer and the internal ring of the needle bearing of 5th gear. [Note: The backing washer must have its external groove directed towards the housing.After 26/04/2004 the back washers of 5th gear are symmetrical and have no particular side for assembly]
23. ⚠ Use the FitterVW 244 and a hammer to correctly position the stop. — Install the 5rdgear cog on the pinion shaft.
24. Install the cog, the synchronizer set and the synchronizer ring and the selector fork of 5th gear on the primary shaft
25. Install the synchronizer body on the primary shaft, in the direction of the arrow.
26. Use a new joint and install the gearbox housing on the differential housing, tightening the screws with 25 Nm. — 25 Nm (18 lb-ft)
27. Engage a gear and block the primary shaft.
28. Install a new nut on the pinion shaft and tighten it with 100 Nm. — 100 Nm (74 lb-ft)
29. Secure the new nut in two positions in the region of the axel bevel, as indicated by the (arrow) in the illustration.
30. Position the claw of the 1st and 2nd gears on the sliding rod.
31. Install the fork selector lever on the gearbox housing with the aid of a screwdriver.
32. Secure the claw of the 1st and 2nd gears with a locking pin.
33. Secure the selector fork of 5th gear with the locking pin.
34. Install the fork selector lever case housing .

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