020 Rebuild Page 8

Now it is time to install the input shaft support beam. Install as shown, and use the center bolt to just support the weight of the input shaft. It will hold the weight of the press during the following operations to prevent the forces from being transmitted through any other parts except the shaft itself....

On the earlier MK3 codes and the MK2 16V codes, install the additional 4th gear circlip into the bottom groove, and sit the input shaft down into the roller bearing, and onto the shaft support beam above...

Install 4th gear onto the output shaft and secure it with a circlip (on 8V trans, the shoulder faces 5th gear). On MK2 16V trans, the 4th is the large style, using 2 circlips to secure it. On the MK3 2.0L trans, up to probably June 1st, 1997 (the same time as the 5th gear retention clip change to a circlip again), the 4th gear is secured by 2 circlips. From June 1, 1997 VW went back to a smaller 4th gear splined area, and they use just one circlip to secure 4th gear again .....

Don't forget the shift fork rod spring in the gearbox, and the reverse relay lever brackets need installed as well....

Install the shift forks into the trans (see THIS PAGE for the fork assembly instructions)....it'll take a little swinging them around and moving them up and down on the rod to get them all to fit in, but they'll go...

Install the reverse idler gear and shaft into the trans, lining the bolt hole in the reverse shaft to point between the 2 case bolt holes as shown....

A little dab of RTV onto the magnet will get it in place (it can't go anywhere once the case is assembled, this just stops it moving around at all)...

Look at that....it looks like a trans almost!

Press the gearbox onto the input shaft as shown, pressing the 2 case halves together in the process. This is why the shaft support beam is needed...

Tighten the 6mm XZN bolts up for the bearing clamping plate to 11 ft-lbs...

Install and tighten the reverse idler shaft bolt (22 ft-lbs) (if it is a button-head Torx bolt, install to 15 ft-lbs)...

Install the rest of the case bolts to 18 ft-lbs....

Press in the input shaft seal as shown....

Whew!!! :D

I'll add more stuff later (like the flange seals, selector assembly, and finishing it up)