Gearbox removal & installation: Installation position, gear wheel for 3rd gear — VW

🧭 Before you start

Fits: platform codes 1H1, 1H2, 1E7

Don't miss

• Retaining ring diameter increased in vehicles with 2.0 l engine.
• Tensioning plate fits only in one position.
• Before installing selector fork, insert lower spring (arrow) for selector rod into clutch housing.
• Retainer for gear wheel for 5th gear in vehicles with 2.0 l engine .
• If the sealing cover was sealed with a sealing ring (4), then this sealing ring must be renewed.

🔩 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.

📋 Procedure

1. Drive on gear wheel for 3rd gear to stop using drift sleeveVW 244 B.
2. Determine thickest retaining ring »which will still fit« and install it. [Note: Retaining ring diameter increased in vehicles with 2.0 l engine.] [Note: If input shaft was not dismantled: pressing off deep groove ball bearing for input shaft]
3. Fit complete input shaft but without deep groove ball bearing. Input shaft is supported by support bridge30 - 211 A, adapterVW 295 A and an M12 lock nut .
4. Fit gear wheel for 4th gear on output shaft, drive on with extension30 - 23 and secure with retaining ring (B).
5. Gear wheel for 4th gear with additional retaining ring (A)

6. Press on input shaft deep groove ball bearing with press toolVW 407.
7. Tighten tensioning plate (arrow) securely. [Note: Tensioning plate fits only in one position.]
8. Before installing selector fork, insert lower spring (arrow) for selector rod into clutch housing.
9. Install selector fork set and align selector jaws.
10. Insert selector rods
11. Align reverse gear wheel shaft. Distances (X) are identical.
12. Drive on gearbox housing, first making sure that input shaft is correctly supported by support bridge30 - 211 A and adapterVW 295 A.
13. Bolt on reverse gear wheel shaft.
14. Tighten hexagon bolts for securing gearbox housing to 25 Nm. — 25 Nm (18 lb-ft)
15. Retighten tensioning plate countersunk screws for deep groove ball bearing to 15 Nm. — 15 Nm (11 lb-ft)
16. Put on gear wheel for 5th gear, drive on if necessary.
17. Install thrust washer and retaining ring. [Note: Retainer for gear wheel for 5th gear in vehicles with 2.0 l engine .]
18. Fit 5th gear synchro-hub complete with locking collar, 5th gear synchromeshed gear with selector fork and new locking plate.
19. Use box spanner3059 to screw selector tube clockwise into selector fork
20. Unscrew selector tube until it projects x = 5.0 mm. [Note: Do not pull selector rod out of the selector tube (may happen if box spanner is tilted). Otherwise the selector forks in the gearbox will fall apart and the gearbox will have to be disassembled again. Hold selector rod down, if necessary, with a screwdriver inserted through the side slot when taking box spanner off.]
21. Coat new bolt for synchro-hub with locking fluidD 000 600 A2 and tighten with a 12 mm multi-point insert. To do this, select 5th gear and reverse gear (forward selector jaw facing downwards).
22. Move selector forks to neutral position before installation of selector shaft.
23. Mask off selector shaft gearing so that seal is not damaged.
24. Insert selector shaft (1).
25. Insert compression spring (2) for selector shaft and tighten sealing cover (3). [Note: If the sealing cover was sealed with a sealing ring (4), then this sealing ring must be renewed.]
26. Insert selector shaft locking bolt (5) with sealing pasteAMV 188 200 03. [Note: Take greatest of care when making setting so that "„jumping out of gear“" will not happen.]
27. Check projection of selector tube dimension x = 5.0 mm. Adjust with box spanner3059 if necessary.
28. Bolt selector shaft lever to selector shaft and engage 5th gear (pull selector shaft fully out and turn to left).
29. Align locking collar (1) with selector fork (2) to 5th gear synchromeshed gear (3) so there is no play.
30. Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.
31. Drive on new locking plate. Support selector fork with tools about 12 mm thick, e.g. two flat open jaw spanners (A) 19 mm and 24 mm.
32. Proceed as follows before setting up cover (arrow): [Note: In gearboxes with paper gasket, put this on first.]
33. Shift through all gears.
34. Install drive flanges.

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