Transmission Housing, Servicing

Transmission housing, servicing





Special tools and equipment
^ VW 408A Press tool
^ VW 423 Tube
^ VW 454 Press piece
^ VW 681 Oil seal extractor
^ VW 771 Multipurpose tool
^ 10-15 Guide pin





Special tools and equipment
^ 30-100 Drift sleeve
^ 30-505 Mandrel
^ 40-503 Press tool
^ 2062 Drift
^ 1 - Kukko 21/5 Internal puller
^ VAG 1331 Torque wrench





Note: Components marked with [1] indicate adjustment work is required if these components are replaced, Refer to Adjustment overview.

1. Flange shaft oil seal
2. Cover plate[1]
^ For final drive
3. O-ring
^ For final drive cover plate
^ Always replace
4. Shim S1
5. Large tapered roller bearing outer race[1]
^ For differential
^ Driving out and in; Refer to Fig. 11 and Fig. 12
6. Small tapered roller bearing outer race[1]
^ For differential
^ Driving out and in; Refer to Fig. 9 and Fig. 10
7. Shim S2
^ Note thickness
^ Refer to Adjustment overview
8. Oil seal
9. Oil drain plug
10. Ball sleeve for selector shaft
11. Ball sleeves for selector rods
12. Circlip
^ Installed position: holes face up
13. Back-up light switch, 20 Nm
^ Removing and installing; Refer to Fig. 12
^ Determine using parts Supplier
14. O-ring
^ For selector shaft cover
^ Always replace
^ Coat with transmission oil when installing
15. Selector shaft cover
16. Ball head pin, 20 Nm
^ For connecting rod
17. Large tapered roller bearing outer race[1]
^ For pinion shaft
^ Pulling out; Refer to Fig. 1
^ Pressing in; Refer to Fig. 2
18. Circlip
^ Removing; Refer to Fig. 16
19. Shim S3
^ Note thickness
20. Needle roller bearing for input shaft
^ Pulling out; Refer to Fig. 13
^ Driving in; Refer to Fig. 14
^ Measuring driving depth; Refer to Fig. 15
21. Selector shaft locking bolt
22. Trunnion bolt, 40 Nm
23. Bleeder
^ Pressing depth of sleeve; Refer to Fig 11
24. Oil seal
^ Only install with fitting sleeve; Refer to Fig. 10
25. Transmission housing[1]
^ With oil pump; Refer to Fig. 17
26. Magnet
^ Clean
^ If transmission housing is replaced, drive in with e.g. press tool VW 408 A
27. Speedometer Vehicle Speed Sensor (VSS)
28. O-ring
^ Always replace
29. Oil filler plug





Fig. 1 Pulling out flange shaft oil seal

Note:
^ Removal from right transmission side is illustrated in figure.
^ The procedure for the oil seal is the same on left and right sides.





Fig. 2 Driving in oil seal
- Half fill space between sealing lip and dust lip with grease G 052 128 A1.
Driving depth: 5.5 mm

Note:
^ Installation in right transmission side is illustrated.
^ The procedure is the same on the left and right sides.
^ If previously used flange shaft is installed, repair depth is 6.5 mm.





Fig. 3 Prying input shaft oil seal out of assembled transmission





Fig. 4 Prying input shaft oil seal out of assembled transmission
- Carefully pry out oil seal with screwdriver.

Note: Do not damage oil seal running surface on input shaft.





Fig. 5 Driving in input shaft oil seal
- Half fill new output shaft oil seal between sealing and dust lips with grease G 052 128 A1.
- Pull thin insulation hose tightly over splines of input shaft.
- Drive on input shaft oil seal.
Driving depth: 3.5 mm

Note: If the used output shaft is reused, repair pressing depth is 4.5 mm.

- Remove insulating hose.





Fig. 6 Pulling out ball sleeve
- Remove circlip.
A - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2





Fig. 7 Driving in ball sleeve
- Set ball sleeve with side bearing lettering (thicker wall) facing drift.
- Drive onto stop
- Install circlip.




Fig. 8 Removing selector shaft oil seal

Note: If transmission is removed but still assembled, carefully pry oil seal out using screwdriver without damaging shaft.





Fig. 9 Driving in selector shaft oil seal
- Selector shaft installed or removed
- Half fill space between sealing lip and dust lip with grease G 052 128 A1.
- Pull fitting sleeve onto selector shaft; Refer to Fig. 10.
- Drive oil seal onto stop in housing.





Fig. 10 Installing oil seal and selector shaft with fitting sleeve

- To prevent damage to oil seal -C-, only install oil seal or selector shaft with fitting sleeve -A-, Part No. 01 E 311 120.





Fig. 11 Pressing depth of bleeder sleeve
Dimension a = 21 mm





Fig. 12 Removing and installing back-up light switch

- When installing, tighten back-up light switch -A- to prescribed torque.

Note: Determine switch according to parts Supplier.





Fig. 13 Pulling needle roller bearing out of transmission housing

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





Fig. 14 Driving needle roller bearing into transmission housing
Installed position: Lettering on bearing facing drift
Driving depth; Refer to Fig. 15





Fig. 15 Driving depth of needle roller bearing

Dimension -a- = 105 mm





Fig. 16 Removing circlip

- Pry one end of circlip out of groove by twisting with screwdriver -A-.
- Use screwdriver -B- to hold this end securely.
- Continue to pry out with screwdriver -A-.





Fig. 17 Transmission housing with oil pump

1. Bolt
2. Oil pump
3. O-ring