Transmission Cover, Servicing

Transmission cover, servicing - 6 Spd. Manual Transmission 02X All Wheel Drive





Special tools, testers and auxiliary items required

^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 408 A
^ Thrust disc VW 412
^ Thrust pad VW 512
^ Sleeve VW 519





Special tools, testers and auxiliary items required

^ Holding fixture VW 801
^ Guide pin 10 - 15
^ Thrust ring 2006 A
^ Tube 2010
^ Tube 2040
^ Centering mandrel 3176

Special tools, testers and auxiliary items required





^ Torque wrench V.A.G 1331





^ - 1 - Internal puller Kukko 21/2
^ - 1 - Internal puller Kukko 21/5
^ - 4 - Counter-support Kukko 22/2





1 - Transmission cover
2 - Dowel sleeve

^ 2x
^ For centralizing transmission cover on bearing housing
^ Drive out and in with drift 3121

3 - Needle bearing

^ Bearing for hollow shaft in transmission cover
^ Pressing out
^ Pressing in

4 - Roller bearing

^ Bearing for input shaft in transmission cover
^ With lubricating unit
^ Always replace
^ Pulling out
^ Pressing in

5 - Ball sleeve

^ For selector rod for 1st and 2nd gear
^ Pulling out
^ Driving in

6 - Ball sleeve

^ For selector rod for 5th and 6th gear
^ Pulling out
^ Driving in

7 - Multi-point socket head bolt, 24 Nm
8 - Retaining plate

^ Installation position





Pressing needle bearing out of transmission cover





Pressing needle bearing into transmission cover

Support transmission cover with tube 2010 directly below bearing mounting.





Pulling out ball sleeve - C - from transmission cover

A - Counter-support, e.g. Kukko 22/2

B - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2





Driving ball sleeve into transmission cover until flush

Install ball sleeve - 1 - and - 2 - so that side with lettering (thicker metal) faces guide pin 10 - 15 or centering mandrel 3176.

Note:
^ Due to the housing depth use centering mandrel 3176 for driving in ball sleeve - 2 -.





Pulling out needle roller bearing from transmission cover

Shorten (cut off) lubricating unit in needle roller bearing in order to insert internal puller - B -.

A - Counter-support, e.g. Kukko 22/2

B - Internal puller 30 to 37 mm, e.g. Kukko 21/5

Note:
^ Always replace needle roller bearing after pulling out.





Carefully press in new needle roller bearing into transmission cover until limit stop.

Support transmission cover below bearing mounting using thrust ring 2006 A.





Securing needle roller bearing and needle bearing in transmission cover.

- Insert retaining plate - 2 - with the high shoulder - arrow - facing needle bearing - 1 - into transmission cover.

- Tighten hex socket head bolt - 3 - to 24 Nm.