Transmission Housing, Shift Mechanism, Input Shaft, Output Shafts, Differential and Selector Rods

Transmission Housing, Shift Mechanism, Input Shaft, Output Shafts, Differential and Selector Rods

Special tools, testers and auxiliary items required

• Holding fixture (VW 309)

• Holding fixture (VW 313)

• Transmission support (VW 353)

• Thrust tube (VW 455)

• Slide hammer-complete set (VW 771)

• Internal extractor (Kukko 21/01)

• Separating tool (Kukko 17/0)

• Support (Kukko 22/1)

• Bracket (30 - 211 A)

• Thrust piece (T10042)

• Drift (T10169)

• Thrust piece (T40008)

• Torque wrench (V.A.G 1331)

• Heat gun (V.A.G 1416)

Disassembly

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





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

- Place drip tray underneath.

- Drain gear oil.

- Remove slave cylinder with release bearing - arrows -.





- Move selector shaft to neutral position, lock elbow - arrow - must not be engaged.





- Remove switch for back up lights - 1 -.

- Remove mounting screw - 2 -.

- Remove bolts - 3 -.

- Pull selector mechanism - 4 - out of transmission housing.

- Remove securing bolt for left and right flange shaft, to do so screw two bolts in flange and counter hold using a pry bar.

- Pull out flange shafts with compression spring.

- 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 thrust tube (VW 455) over input shaft onto clutch housing.





- Then tension separating tool - A -, e.g. (Kukko 17/0) tightly behind input shaft splines.

During this, back side of separating tool must contact thrust tube free of play.

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





- Remove cap from transmission housing.

A Support, e.g. (Kukko 22/1)
B Internal puller 8 to 12 mm, e.g. (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 a screwdriver - B - pry other end out of groove of grooved ball bearing in direction of- arrow -.

- By repositioning screwdriver - B -, pry circlip out further.

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





- Screw adapter (VW 771/40) into threaded hole of transmission housing.





- Heat transmission housing using hot air gun, e.g. (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to approximately 100° C 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 thrust tube (VW 455) from input shaft.





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

- Lift differential - 1 - using 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.

- Remove seal for input shaft.

• Grooved ball bearing on input shaft must always be replaced --> [ 4 Grooved ball bearing ] Input Shaft.

Assembly

• Press a new grooved ball bearing onto input shaft --> [ 4 Grooved ball bearing ] Input Shaft.

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





- Insert differential - 1 -.





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

- Lift differential - 1 - slightly with 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.

- 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.

- Secure bracket (30 - 211 A) for input shaft on clutch housing.





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

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

- Heat transmission housing using (heat gun), e.g. (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to approximately 100° C for approximately 10 minutes.

- 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 bracket (30 - 211 A) for input shaft.

- If lock sleeve for selector shaft has been removed, drive it in now using drift (T10169) until tool makes contact.





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

- Insert selector shaft - 1 - into lower bearing - 2 - and into shift forks - 3 -. Cap is removed in illustration for reasons of clarity.





- 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.

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

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

- Tighten bolts - 3 - for cover/selector shaft - 4 -.





- Screw in mounting screw - 2 -, lock elbow - arrow - must lie outside.

- Install switch for back up lights - 1 -.

- Install left and right flanged shafts with compression springs, thrust washers and tapered rings.

- Drive in input shaft seal.





- Install slave cylinder with release bearing and tighten bolts - arrows - to tightening specification--> [ 4 Bolt ] Clutch Release Mechanism Assembly Overview.





- Shift through all gears.

- Drive cap into transmission housing up to stop of thrust piece (T10042)