Transmission Housing
Transmission Housing
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Transmission Support (VW 353)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Tube 37 mm Dia. (VW 416 B)
• Guide Piece (VW 436 A)
• Guide Pin (VW 439)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Guide Piece (10-15)
• Thrust Pad (3124)
• Bearing Driver (3264)
• Subframe Support Assem. Device (3290)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Drift (T10169) or (T10362)
• Drift (T10168)
• Thrust Piece (T10203)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Extractor 23.5-30 mm (21/4)
• Kukko Support (22/2)
• Threaded Adapter from Kukko Support (22/1)
Removing the sealing cap
- Pierce the rubber sealing cap - A - in the center with a screwdriver - B - and pry it out in the - direction of the arrow -.
Installing the sealing cap
Removing the locking pin for the gear shift shaft
- Break off the locking pin in its unlocked position.
- Insert a screwdriver - A - into the hole in the locking pin - B -.
- Pry out the locking pin in the - direction of the arrow -.
Installed position: locking pin
• The mark on the locking pin - arrow - must point toward the connection on the clutch slave cylinder - 1 -.
• Dimension - a - must be approximately 45°.
Drive the locking pin - arrow - for the shift shaft in up to the tool stop
• The locking pin must be unlocked when being installed.
Removing the selector shaft bushing
A Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm (21/2)
B Counter support, for example, Kukko support (22/2)
Installing the selector shaft bushing all the way in up to the tool stop
Removing the retaining sleeve - A - from the transmission housing
- Place the transmission housing on the thrust plates (VW 401) and (VW 402) without damaging the alignment sleeves in the transmission housing.
Removing the retaining sleeve on a assembled transmission using the guide piece (10-15)
• Locking screw and selector shaft are removed.
- Turn the transmission so that the retaining sleeve cannot fall into the transmission.
Locking Sleeve Differentiation
The following locking sleeves may be installed:
Locking sleeve with a shoulder - arrow 1 -. Refer to => [ Drive in the locking sleeve with a shoulder as far as the stop on the tool ].
Locking sleeve without a shoulder - arrow 2 -. Refer to => [ Drive in the locking sleeve without a shoulder as far as the stop on the tool ].
Allocate the components using the Parts Catalog.
Drive in the locking sleeve with a shoulder as far as the stop on the tool
• The transmission housing is bolted to the clutch housing.
Drive in the locking sleeve without a shoulder as far as the stop on the tool
• The transmission housing is bolted to the clutch housing.
Removing the reverse gear shaft needle sleeve from the transmission housing
A Internal puller 23.5 to 30 mm, for example, Kukko extractor 23.5-30 mm (21/4)
B Counter support, for example, Kukko support (22/2)
• The needle sleeve will get damaged when it is removed and must be replaced.
Installing the needle sleeve - A - into the transmission housing
- Lay the reverse gear shaft thrust washer - B - on the needle sleeve while pressing it in.
- Support the transmission housing beneath the bearing mount using the tube 37 mm dia. (VW 416 B).
Removing the gear shift shaft bushing
- Use the threaded adapter from the Kukko support (22/1) - arrow -.
- Hold the spindle on the subframe support assm. device (3290) steady and turn the nut - B -.
A Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm (21/2)
Installing the gear shift shaft bushing - A - all the way in to the too stop
Removing the sealing cap plug
- Remove the sealing cap - 1 - from the inside of the transmission housing to the outside.
Installing the sealing cap
- Install the sealing caps approximately 3 mm under the upper edge of the housing - a - using the bearing driver (3264).