Install The Gear Carrier On The Transmission Cover As Follows:
- Installed position: the tab -arrow A- on the gear carrier -2- must installed into the opening -arrow B- inside the transmission cover.
-- Install the oil catch tray -1-.
-- Mount the spacer sleeve -3- and the adjusting shim -4- (for positioning the center differential) on the output shaft.
-- Slide the center differential -2- all the way in direction of the gear carrier -1-.
-- Insert the plate spring -5-, the adjustment shim(s) -4- and the spring -3- in the center differential housing -6-.
- Plate spring installed position -5- : the inner diameter with it camber -arrow- faces the center differential housing -6-.
-- Apply sealing paste AMV 188 001 02 evenly and not too thick.
-- Then position the center differential housing -6- on the transmission.
-- Press the center differential housing -C- on until it makes contact with the transmission cover and hold it securely.
-- Install the new bolts -A-, -B- and -arrows- and tighten them to the tightening specification.
Not all versions have the double bolts -B- ; allocation, Bolts are installed in place of the double bolts -2- CENTER DIFFERENTIAL HOUSING AND CENTER DIFFERENTIAL ASSEMBLY OVERVIEW .
-- Install the new O-ring on the cover -2-.
-- Install the T40216 on the selector shaft -1-.
-- Insert the selector shaft in the transmission -arrow A- by raising it slightly -arrow B-.
-- Bring the selector shaft cover -2- into contact with the transmission housing.
-- Tighten the new bolts -1- to the tightening specification.
-- Remove T40216.
-- If equipped, install the transmission neutral position sensor -G701- -A- with a new O-ring in the gearshift shaft cover -B-.
-- Tighten new bolt -1- to the tightening specification.
-- Install the guide sleeve -6- and the locking plate -5-, if equipped.
-- Clean bolt threads -4- with a wire brush. Then install and tighten the bolts with locking fluidAMV 185 101 A1 to the tightening specification -6- CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW => Bolt .
Noises when actuating the clutch
- Rattling noises can occur when pressing the clutch if there is not enough grease on the release bearings.
- Lubricate the release bearings with adhesive lubricating paste G 000 150. Refer to CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW .
- Remove any grease still in the guide sleeve bearing area.
-- Install the clutch release lever -1- together with the release bearing -2- and the spring -3-. Refer to CLUTCH RELEASE MECHANISM ASSEMBLY OVERVIEW .
Check which version of the needle bearing is inside the dual mass flywheel.
- Needle bearings is missing the 4th roller -arrows- must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to DUAL MASS FLYWHEEL NEEDLE BEARING, SACHS AND LUK .
- New needle bearings are equipped with rollers.
- On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!
-- Install the clutch module and the left flange shaft INSTALL THE CLUTCH MODULE .
-- Fill the transmission with transmission fluid and check the level. Refer to GENERAL INFORMATION . Remove the oil filler plug -arrow-.