Transmission, with a Sealing Cap Circlip or Plastic Cover
Transmission, with a Sealing Cap Circlip or Plastic Cover
The plastic cover for the input shaft does not require the securing ring - A -.
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Tube (VW 455) or Sleeve (3160)
• Slide Hammer-Complete Set (VW 771)
• Kukko Puller 12-14.5 mm (21/1)
• Kukko Separating Tool 5-60 mm (17/0)
• Kukko Support (22/1)
• Bracket (30-211 A)
• Thrust Piece (T10143) or Press Tool for Shaft Seal (T10180)
• Drift (T10169) or (T10362) , see => [ Retaining sleeve differentiation ] Transmission Housing.
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Hot Air Blower (V.A.G 1416)
• Drip Tray for VAS 6100 (VAS 6208)
Disassembly
- Attach the transmission to the transmission support with bolts - arrows -.
• If one of the bolt holes does not touch the transmission support place shims between the hole and the transmission support.
- Turn the transmission in the support so that the drain plug is facing down.
- Place the drip tray underneath.
- Drain the fluid from the transmission.
- Remove the right flange shaft (the illustration shows the left flange shaft). To do this, install two bolts into the flange and counter hold the flange using a pry bar.
- Remove the slave cylinder with the release bearing bolts - arrows - and slave cylinder.
Make sure the gear shift shaft is not blocked by the locking pin - arrow -.
- Move the gear shift shaft into neutral.
- Remove the backup lamp switch - 1 -.
- Remove the locking screw - 2 -.
- Then, remove the bolts - 3 -.
- Remove the gear shift unit - 4 - from the transmission housing.
- Remove the left flange shaft bolt. To do this, install two bolts into the flange and counter hold the flange using a pry bar.
- Remove the left flange shaft and the pressure spring.
- Remove the bolts - B - that connect the clutch housing to the transmission housing.
• One bolt - arrow - is located outside of the bolting flange.
- Secure the input shaft as follows:
The stub shaft splines on the input shaft has different lengths on the transmission.
- Either place the thrust tube (VW 455) over the input shaft on the clutch housing.
- Or, place the sleeve (3160) over the input shaft on the clutch housing.
- Tension the separating tool - A -, for example, Kukko separating tool 5-60 mm (17/0) , tightly behind the splines on the input shaft.
The back of the separating tool must touch the thrust tube (VW 455) or the sleeve (3160) free of play.
With a Metal Sealing Cap
- Remove the circlip - A -.
- Pierce the center of the rubber cover - C - using a screwdriver.
- Remove the cover from the transmission housing.
A Counter support, for example, Kukko support (22/1)
B Internal puller 8 to 12 mm, for example, Kukko puller 12-14.5 mm (21/1)
With a Plastic Sealing Cap
Carefully remove all the tabs - A -. Do not damage the transmission housing when doing so.
- Pry out the sealing cap.
• Ensure that the individual pieces of the sealing cap are removed as necessary.
Continuation for All
Remove the lock ring - C - from the grooved ball bearing on the input shaft/transmission housing as follows:
- Hold one end of the lock ring secure using a screwdriver - A -.
- Pry the other end out of the groove in the grooved ball bearing in the - direction of the arrow - using the screwdriver - B -.
- Pry out the rest of the lock ring using the screwdriver - B -.
- Remove the bolts - A - that secure the transmission housing to the clutch housing.
- Install adapter for VW 771 slide hammer (VW 771/40) into the threaded hole in the transmission housing.
- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, hot air blower (V.A.G 1416).
- Remove the transmission housing from the clutch housing in the - direction of the arrow - using the slide hammer (VW 771/1).
• If necessary, carefully pry up all around and alternate between sides on the protruding flange. Be careful not to damage the sealing surfaces.
- Remove the separating tool - A - and the thrust tube (VW 455) (illustration) or the sleeve (3160) from the input shaft.
A second technician is needed to help remove the shafts from the clutch housing.
- Lift the differential - 1 - with the left hand. With the right hand, lift the output shaft for 1st to 4th gear together with the selector shafts - 2 - - arrow A -.
- At the same time, the 2nd technician lifts the input shaft, reverse and output shaft for 5th/6th gear and reverse gear shaft - 3 - together with the selector shafts out of the clutch housing - arrow B -
• If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.
- Removing the input shaft seal.
• Always replace the grooved ball bearing (- item 6 - in the => [ Input Shaft Overview ] Input Shaft Overview) on the input shaft.
Assembly
• Press the new grooved ball bearing (- item 6 - in the => [ Input Shaft Overview ] Input Shaft Overview) onto the input shaft.
- Install the input shaft - 1 -, the 5th/6th gear and reverse gear output shaft - 2 -, the selector shaft - 3 -, the reverse gear selector fork - 4 - and reverse gear shaft - 5 -.
Pay attention to the different bearings for the reverse gear selector fork.
The reverse gear selector fork - 1 - is mounted on the axle - 2 - behind the 5th and 6th gear selector shaft - 3 -.
The reverse gear selector fork - 1 - is mounted on the selector shaft with the 5th and 6th gear selector fork - 2 -.
Continuation for All
- Then, install the differential - 1 -.
• A 2nd technician is needed to help install the shafts into the clutch housing.
- Hold the output shaft for 1st through 4th gear - 3 - and the selector shafts - 4 - with the right hand.
- Slightly lift the differential with the left hand.
- Have the second technician lift the input shaft, the 5th/6th gear output shaft and reverse gear - 2 - together with the reverse gear shaft slightly at the same time.
- Install the 1st to 4th gear output shaft in the - direction of the arrow -.
• Parts of the input shaft, output shafts and final drive gear/differential must engage.
- Together with a second technician, now place the shafts and differential in their bearing seats.
- install the bracket (30-211 A) to the input shaft and the clutch housing.
• The clutch housing is shown in the illustration rotated 180°.
- Install the bolt - A - just far enough until the input shaft starts to lift.
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 the flattened areas - A and B - are present, do not insert any washers above and below the grooved ball bearing. Refer to => [ Grooved Ball Bearing Changes ] Input Shaft.
• 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.
- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see the next graphic).
- Heat the transmission housing in the area around the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, hot air blower (V.A.G 1416).
• 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 mark on the grooved ball bearing - A - with the mark on the transmission housing - B - and mount the transmission housing.
- Install the transmission housing and tighten the new bolts - A, B and C - to specification.
If the steel bolts (outer hex head) are the replacement part, pay attention to the allocation:
A Bolt with a permanent washer
B Bolt without washer
C Bolt with a permanent washer
- Install the grooved ball bearing/input shaft lock ring - 1 -.
- Remove the bracket (30-211 A) for the input shaft.
- Install the selector shaft lock sleeve all the way onto the tool. Refer to => [ Retaining sleeve differentiation ] Transmission Housing.
- Turn the transmission with the opening for the selector shaft in the assembly stand upward.
- Install the gear shift shaft - 1 - into the lower bearing - 2 - and into the selector forks - 3 -.
• The cover (- item 2 - in the => [ Transmission Housing ] Transmission Housing) is not shown in the illustration.
- Push the gear shift shaft - 1 - against the retaining sleeve - 2 - in the - direction of the arrow - and guide is through the selector fork all the way down using the shift finger - 3 -.
• The gear shift unit - 4 - must be parallel to the bolting surface on the transmission housing.
• It must be possible to move the gear shift shaft easily (forward and backward).
• If the gear shift unit is at an angle to the bolting surface, then the gear shift shaft is not installed into the lower bearing.
- Tighten the bolts - 3 - for the gear shift unit - 4 -.
- Install the locking screw - 2 -, the locking pin - arrow - must not be installed when doing so.
- Install the backup lamp switch - 1 -.
- Install the input shaft seal flush.
- Install the slave cylinder with release bearing. Refer to => [ Clutch Release Mechanism Overview ] Description and Operation.
- Move the shift lever through all the gears.
- Install the sealing cap as follows:
Sealing Cap Differentiation
- I - = metal sealing cap, secured with a circlip - A -.
- II - = plastic sealing cap, without a circlip.
Allocation
Metal Sealing Cap
- Install the sealing cap all the way into the transmission housing.
- Secure the cap with the circlip- A -.
Plastic Sealing Cap
- Install the cap all the way into the transmission housing.
Continuation for All
• Always pay attention to the sealing cap allocation. Refer to => [ Allocation ].
• Leaks in the case if incorrectly installation.
• For the correct sealing cap, refer to the Parts Catalog.
- Install the left flange shaft and pressure spring, the thrust washer and the tapered ring.
- Install the right flange shaft and pressure spring, the thrust washer and the tapered ring.