Transmission Housing, Servicing
Transmission Housing, Servicing
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 (VW 416 B)
• Guide pin (VW 436A)
• Guide pin (VW 439)
• Slide hammer-complete set (VW 771)
• Holding plate (VW 801)
• Guide pins (10 - 15)
• Thrust piece (3124)
• Driver (3264)
• assembly tool (3290)
• Torque wrench (V.A.G 1331)
• Drift (T10168)
• Drift (T10169)
• Thrust piece (T10203)
• Internal extractor (Kukko 21/2)
• Internal extractor (Kukko 21/4)
• Support (Kukko 22/2)
1 Transmission housing
• When replacing: Adjust output shafts and differential --> [ Adjustment Overview ] Adjustment Overview.
2 Sealing cap
• Removing --> [ Removing Cap ]
• Driving in --> [ Drive in Cap Until Stop ]
3 Oil drain plug
• Note different versions --> [ Different Versions of Oil Fill and Oil Drain Plugs ]
• With multi point socket head, 45 Nm
• With hex-socket head, 30 Nm
4 Seal
• Always replace
5 Oil filler plug
• Note different versions --> [ Different Versions of Oil Fill and Oil Drain Plugs ]
• With multi-point socket head, 45 Nm
• With hex-socket head, 30 Nm
6 Lock elbow
• For adjustment of selector mechanism --> [ Selector Mechanism, Adjusting ] Adjustments.
• Can be replaced with non-disassembled transmission
• Removing --> [ Removing Lock Elbow for Selector Shaft ]
• Installed location --> [ Installation Position of Lock Elbow ]
• Driving in --> [ Drive Lock Bracket for Selector Shaft in Up To Tool Stop ]
7 Bushing
• For selector rods
• Pulling out --> [ Pulling Out Bearing Bushing for Selector Rod ]
• Driving in --> [ Driving in Bearing Bushing for Shift Rod to Tool Stop ]
8 Lock sleeve
• Pressing off with transmission disassembled --> [ Pressing Lock Sleeve Out of Transmission Housing ]
• Driving off with non-disassembled transmission --> [ Driving Out Lock Sleeve for Non-Disassembled Transmission Using ]
• Driving in --> [ Driving in Lock Sleeve Until Tool Stop ]
9 Needle sleeve
• For reverse shaft
• Always replace after removal
• Pulling out --> [ Pulling Needle Sleeve for Reverse Shaft Off Transmission Housing ]
• Pressing in --> [ Pressing Needle Bearing into Transmission Housing ]
10 Tapered roller bearing outer race
• For output shaft for 5th/6th and reverse gear
• Removing and installing --> [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• When replacing: Adjusting output shaft for 5th/6th and reverse gear --> [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
11 Shim
• For output shaft for 5th/6th and reverse gear
• List of adjustments --> [ Adjustment Overview ] Adjustment Overview.
12 Tapered roller bearing outer race
• For output shaft for 1st to 4th gear
• Removing and installing --> [ Output Shaft, 1st through 4th Gears ] Output Shaft, 1st through 4th Gears.
• When replacing: Adjusting output shaft for 1st to 4th gear --> [ Output Shaft, 1st through 4th Gears, Adjusting ] Output Shaft, 1st through 4th Gears, Adjusting.
13 Shim
• For output shaft for 1st to 4th gear
• Adjustment overview --> [ Adjustment Overview ] Adjustment Overview.
14 Tapered roller bearing outer race
• For differential
• Removing and installing --> [ Differential ] Service and Repair.
• When replacing: Adjusting differential --> [ Adjustment Overview ] Adjustment Overview.
15 Shim
• For differential
• List of adjustments --> [ Adjustment Overview ] Adjustment Overview.
16 Bushing
• For selector shaft
• Pulling out --> [ Pulling Out Bearing Bushing for Selector Shaft ]
• Driving in --> [ Driving Bearing Bushing for Selector Shaft in to Tool Stop ]
17 Sealing plugs
• Driving out --> [ Driving Out Sealing Plugs ]
• Driving in --> [ Driving In Sealing Plugs ]
18 Seal
• Replace --> [ Removal and Installation ]
Removing Cap - A -
- Knock rubber through at center of sealing cap using a screwdriver - B - and pry out cap in direction of - arrow -.
Drive in Cap Until Stop
Different Versions of Oil Fill and Oil Drain Plugs
I Oil filler and oil drain plug with multi point socket head
II Oil filler and oil drain plug with hex socket head
Removing Lock Elbow for Selector Shaft
- Break off bracket in released position.
- Guide a screwdriver - A - into hole of lock elbow - B -.
- Pry out lock bracket in direction of - arrow -.
Installation Position of Lock Elbow
• Marking on lock elbow - arrow - must point to slave cylinder connection - 1 -.
• Dimension - a - must be approximately 45 degrees.
Drive Lock Bracket - arrow - for Selector Shaft in Up To Tool Stop
• Lock elbow must be released for driving in procedure.
Pulling Out Bearing Bushing for Selector Rod
A Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
B Support, e.g. (Kukko 22/2)
Driving in Bearing Bushing for Shift Rod to Tool Stop
Pressing Lock Sleeve - A - Out of Transmission Housing
- Arrange transmission housing on thrust plates (VW 401) and (VW 402) so that alignment bushings in transmission housing are not damaged.
Driving Out Lock Sleeve for Non-Disassembled Transmission Using Guide Pin (10 - 15)
- Beforehand, remove mounting screw and selector shaft.
- Rotate transmission so that lock sleeve does not fall into transmission.
Driving in Lock Sleeve Until Tool Stop
Drive in lock sleeve using drift (T10169) only, when transmission housing is attached to clutch housing.
Pulling Needle Sleeve for Reverse Shaft Off Transmission Housing
A Internal puller 23.5 to 30 mm, e.g. (Kukko 21/4)
B Support, e.g. (Kukko 22/2)
• Needle sleeve is destroyed when it is removed and must be replaced.
Pressing Needle Bearing - A - into Transmission Housing
- During pressing sequence, place thrust washer - B - for reverse shaft on needle bearing.
- Support transmission housing directly beneath bearing mount using tube (VW 416 B).
Pulling Out Bearing Bushing for Selector Shaft
- Hold spindle of assembly tool (3290) firmly in place and screw nut - B -.
A Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
Driving Bearing Bushing - A - for Selector Shaft in to Tool Stop
Driving Out Sealing Plugs - 1 -
- Drive sealing plugs - 1 - from interior of transmission housing toward outside.
Driving In Sealing Plugs - 1 -
- Drive in sealing plugs using bearing driver (3264) to dimension - a - approximately 3 mm under lower edge of housing.