Transmission With Retaining Ring For Cover/Input Shaft, Assembly Sequence

Transmission with Retaining Ring for Cover/Input Shaft, Assembly Sequence






Special tools, testers and auxiliary items required

• Holding Plate (VW 309)

• Holding Fixture (VW 313)

• Transmission Support (VW 353)

• Pressing Sleeve (VW 455)

• Slide Hammer (VW 771)

• Internal Puller (Kukko 21/01)

• Separating Tool (Kukko 17/0)

• Counter-Support (Kukko 22/1)

• Bracket (30-211A)

• Thrust Piece (T10042)

• Thrust Piece (T40008)

• Torque Wrench (V.A.G 1331)

• Heat Gun (V.A.G 1416)

• Drift (T10169)

• or Drift (T10362) => [ Lock Sleeve Differentiation ] Transmission Housing

Removing

- Secure transmission to assembly stand with bolts - arrows -.

• If one of the fastening holes does not contact the Transmission Support , place shims between fastening hole and Transmission Support.






- Rotate transmission in assembly stand with oil drain plug downward.

- Place drip tray underneath.

- Drain gear oil.

- Remove slave cylinder with release bearing - arrows -.






In the following step, ensure selector shaft is not locked by the lock elbow - arrow -.






- Move shift shaft to neutral position.

- Remove mounting bolt - 2 -.

- Then remove bolts - 3 -.

- Remove back-up lamp switch (F4) - 1 -.

- Pull selector shaft - 4 - off transmission housing.

- Remove the flange shafts.

- Remove bolts - B - inside clutch housing for securing clutch housing to transmission housing.






• One bolt - arrow - is located outside of bolting flange.

- Secure input shaft by inserting (VW 455) over input shaft onto clutch housing.






- Then tension Separating Tool - A -, for example (Kukko 17/0) tightly behind input shaft splines.

During this, back side of Separating Tool must contact Pressing Sleeve free of play.

- Remove the cap/input shaft circlip - A -.






- Knock rubber through in center of cap - C - using a Screwdriver.






- Remove cap from transmission housing.

A Support , for example (Kukko 22/1)
B Internal Puller 8 to 12 mm , for example (Kukko 21/01)

Remove circlip - C - from grooved ball bearing of input shaft/transmission housing as follows:






- Hold one end of circlip in place using Screwdriver - A -.

- Using Screwdriver - B -, pry other end out of groove for grooved ball bearing in direction of - arrow -.

- By repositioning Screwdriver - B -, pry the circlip out further.

- Remove mounting bolts - A - for transmission housing at clutch housing.






- Screw Adapter VW 771/40 into threaded hole of transmission housing.






- Heat transmission housing using Heat Gun (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to 100 °C / 212 °F for approximately 10 minutes.

- Remove transmission housing from clutch housing using Slide Hammer VW 771/1 in direction of - arrow -.

• If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.

- Remove Separating Tool - A - and Pressing Sleeve VW 455 from input shaft.






A 2nd technician is required to remove shafts from clutch housing.

- Lift differential - 1 - with the left hand. With the right hand, lift output shaft for 1st to 4th gears together with selector rods - 2 - - arrow A -.






- At the same time, 2nd technician lifts input, reverse and output shaft for 5th/6th gear - 3 - together with selector rods out of clutch housing - arrow B -.

• If necessary, differential can be shifted again in clutch housing after lifting shafts.

- Drive out sealing ring for input shaft using Sleeve (30-21).

• Grooved ball bearing on input shaft must always be replaced => [ (Item 8) Input Shaft ] Input Shaft Overview.

Installing

• A new grooved ball bearing must be pressed on to input shaft => [ (Item 8) Input Shaft ] Input Shaft Overview.

- First insert input shaft - 1 -, output shaft for 5th/6th gears - 2 - together with selector rod - 3 -, shift fork - 4 - and reverse shaft - 5 -.






- Then insert differential - 1 -.






• A 2nd technician is required for further installation of shafts into clutch housing.

- As shown in illustration, take output shaft for 1st to 4th gears - 3 - with selector rods - 4 - in right hand.

- Lift differential slightly with the left hand.

- At the same time, 2nd technician slightly lifts input shaft, output shaft for 5th/6th gears and reverse gear - 2 - together with reverse shaft.

- Now, insert output shaft for 1st to 4th gears in direction of - arrow -.

• Splines of input shaft, output shafts and final drive gear/differential must engage.

- Together with a second technician, now displace shafts and differential in their bearing seats.

- Fasten the (30-211A) for the input shaft to the clutch housing.






• For the sake of illustration, clutch housing is depicted rotated 180°.

- Screw in bolt - A - far enough until input shaft rises slightly.

The Grooved Ball Bearing/Input Shaft Only Fits in One Position in the Transmission Housing.





There is a flattened area on the grooved ball bearing and the bearing mount.

• If flattened areas - A - and - B - are present, then do not install the washer => [ From transmission build date 4.10.06 through approximately 1.21.08 ] Transmission Without Cap/Input Shaft Retaining Ring Assembly Sequence.

• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.

- Mark the flattened side with color.

- Place a marking on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (see next illustration).

- Heat transmission housing using Heat Gun (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to 100 °C / 212 °F for approximately 10 minutes.

• It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

• Apply Sealing Paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.

• Align the marking on the grooved ball bearing - A - with the marking on the transmission housing - B - and mount the transmission housing.






- Install transmission housing and tighten new bolts - A -, - B - and - C - to tightening specification.






Allocation of bolts:

A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer

- Install circlip - 1 - for grooved ball bearing/input shaft.






- Remove the input shaft Bracket (30 - 211 A).

- If selector shaft lock sleeve has been removed, drive it in now as far as stop on tool => [ Lock Sleeve Differentiation ] Transmission Housing.

- Turn transmission with opening for selector shaft in assembly stand upward.

- Insert selector shaft - 1 - into lower mounting - 2 - and into shift forks - 3 -.






• To improve clarity, the cap is removed.

- Now press selector shaft - 1 - against lock sleeve - 2 - in direction of - arrow - and guide downward with shift finger - 3 - through shift forks until stop.






• Shift cover - 4 - must stand parallel to bolting surface on transmission housing during this.

• Selector shaft must be able to be moved easily in selector motion (up and downward).

• If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.

- Tighten the bolts - 3 - for the shift cover - 4 -.






- Install lock screw - 2 -, lock elbow - arrow - must not be installed when doing so.

- Install Back-Up Light Switch (F4) - 1 -.

- Install the flange shafts with the springs, thrust washers and tapered rings.

- Drive the cap into the transmission housing as far as the stop.






- Secure the cover and retaining ring - A - (approximately from transmission build date 21 01 8).