Gearbox assembly (VW Passat B2)

Remove the outer ring of the front tapered roller bearing of the secondary shaft, having first removed the cylindrical pin on the 013 type gearbox and unscrewed the hexagonal socket bolt on the 093 type gearbox. If necessary, press in a new ring.

Set the shift fork rod locks and retainers to the correct position.

Install the secondary shaft with the 1st and 2nd gear shift fork into the gearbox housing.

Install the reverse intermediate gear onto the axle, then press the axle in place.

Install the primary shaft with the shift fork for III and IV gears into the crankcase.

Set the fork rods for shifting 1st and 2nd gears, as well as the forks for engaging 5th gear and reverse gear to the neutral position.

Install the fork rod of the 3rd and 4th gears together with the retainer pre-lubricated with consistent grease, insert the spring pin into the fork, holding the rod with a hammer.

Press on the first inner race of the secondary shaft rear double-row tapered roller bearing.

Install the thrust washer on the primary shaft with the protruding part towards the gearbox housing. Heat to a temperature of about 120°C and install the inner ring of the 5th gear bearing in place until it stops, using a 30-23 mandrel if necessary. Hold the primary shaft in place.

Heat to a temperature of about 120°C and install the V gear on the secondary shaft, pushing it all the way, using a 30-100 mandrel if necessary. Hold the secondary shaft in place.

Place the 5th gear pinion on the primary shaft together with the hub and the synchronizer sliding sleeve, the needle bearing and the 5th gear engagement fork. Secure the fork to the rod with a spring pin, holding the rod with a hammer.



Install the 5th gear synchronizer locking ring.

Heat to a temperature of about 120°C and install the synchronizer of the 5th gear in place. If necessary, using the 30-23 mandrel, push it all the way onto the primary shaft. At the same time, lock the primary shaft.

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Install a new sealing gasket and attach the gearbox housing with the installed primary and secondary shafts to the clutch housing. Replace the mounting studs and tighten the housing mounting bolts to a torque of 2.5 kgf·m.

Engage any gear and lock the primary shaft with lock 29441.

Tighten the nut on the rear end of the secondary shaft to a torque of 10.0 kgf·m and lock it.

Move the fork rod of the 1st and 2nd gears forward and engage 3rd gear by pulling the fork rod back.

Install the gear selector shaft:

• place the ends of the spring on the fork rod of the III and IV gears;
• push the gear selection rod lever onto the fork rod of III and IV gears;
• align the gear selector rod and insert it into the guide sleeve.

Set the fork rods to neutral position.

Align the holes in the leash and the fork rod of the first and second gears and insert the spring pin.

Install a new sealing gasket and reinstall the rear gearbox housing cover using an M10 threaded rod.

Tighten the hex bolt at the rear end of the input shaft to a torque of 4.5 kgf·m.

Tighten the rear crankcase cover mounting bolts to a torque of 2.5 kgf.m, having first applied a special adhesive such as VW D3 to their threads.

Install a new plug into the rear cover of the gearbox housing.