Transmission
Transmission
=> [ Disassembly ]
=> [ Assembly ]
• A metal or plastic sealing cap may be installed for the input shaft.
The circlip - A - has been discontinued together with the plastic sealing cap for the input shaft.
• - I - = Metal sealing cap for the input shaft, with a circlip - A -
• - II - = Plastic sealing cap for the input shaft, without a circlip
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Tube (VW 455)
• 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)
• Press Tool for Shaft Seal (T10180)
• Drift (T10169) or (T10362)
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Inductive Heat Unit (V.A.G 1416)
• Drip Tray for VAS 6100 (VAS 6208)
Disassembly
- Attach the transmission to the assembly stand with the bolts - arrows -.
• If one of the holes does not touch the transmission support place shims between the hole and the transmission support.
- Turn the transmission in the assembly stand, until the oil drain plug faces down.
- Place a drip tray underneath.
- Drain the transmission fluid.
- Remove the clutch slave cylinder with release bearing bolts - arrows - and slave cylinder.
Make sure the gear shift shaft is not locked by the locking pin - arrow -.
- Move the gear shift shaft into neutral.
- Remove the backup lamp switch (F4) - 1 -.
- Remove the locking screw - 2 -.
- Then, remove the bolts - 3 -.
- Remove the gear shift shaft with shift cover - 4 - from the transmission housing.
- Remove the left and right flange shaft bolts. To do this, install two bolts into the flange and counter hold the flange shaft using a pry bar.
- Remove the flange shafts and the pressure springs.
- Remove the bolts - B - that connect the clutch housing to the transmission housing.
• One bolt - arrow - is located outside of the bolting flange.
- Lock 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.
Metal Sealing Cap:
- Remove the sealing cap/input shaft circlip - A -.
- Pierce the rubber piece in the center of the sealing cap - C - using a screwdriver.
- Remove the sealing cap 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)
• Can push through the center of the sealing cap for removal of the sealing cap - 1 -
• Pry the sealing cap - 2 - carefully off the transmission housing.
Plastic Sealing Cover:
Carefully remove all tabs - A -. Do not damage the transmission housing when doing so.
- Pry out the sealing cap.
• Make sure the individual parts of the cover are removed, if necessary.
Continuation for all:
Remove the locking ring - C - from the grooved ball bearing on the input shaft/transmission housing as follows:
- Hold one end of the locking ring secure with a screwdriver - A -.
- Pry the other end out of the groove in the grooved ball bearing in the - direction of the arrow - using the a screwdriver - B -.
- Pry out the rest of the locking ring using the screwdriver - B -.
- Remove the bolts - A - that attach the transmission housing to the clutch housing.
- Install adapter (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, inductive heat unit (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) 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 with selector forks - 2 - - arrow A -.
- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear and reverse gear - 3 - together with the selector shafts with selector forks out of the clutch housing - arrow B -
• If necessary, the differential can be shifted again in the clutch housing after lifting shafts.
- Remove the input shaft seal.
• Always replace the grooved ball bearing - item 4 - in => [ Input Shaft Overview ] Input Shaft Overview on the input shaft.
Assembly
• Press the new grooved ball bearing - item 4 - in => [ Input Shaft Overview ] Input Shaft Overview onto the input shaft.
• The reverse gear selector fork - 1 - is placed in its installed position on the 5th and 6th gear selector shaft with selector fork - 2 -.
- Install the input shaft - 1 -, the 5th/5th gear output shaft - 2 - and the 5th/6th gear selector shaft with selector fork - 3 -, the reverse gear selector fork - 4 - and reverse gear shaft - 5 -.
• The shift jaw - arrow A - on the reverse gear selector fork faces the outside of the transmission. The shift jaw - arrow B - on the 5th/6th gear selector shaft with selector fork must face toward the inside of the of the transmission.
- Then, install the differential - 1 -.
• A 2nd technician is needed to help install the shafts into the clutch housing.
- Hold the 1st through 4th gear output shaft - 3 - with the selector shaft with selector fork - 4 - in the right hand as illustrated.
- Lift the differential slightly with the left hand.
- Have the second technician lift the input shaft, the 5th/6th gear output shaft - 2 - together with the reverse gear shaft slightly at the same time.
- Install the 1st through 4th gear output shaft in the - direction of the arrow -.
• Parts of the input shaft, output shafts and final drive gear/differential must engage.
- Place the shafts and the differential in their busing seats with help from a second technician.
- Install the bracket (30-211 A) for the input shaft to 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.
• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.
- Mark this flat side with a colored mark.
- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (=> next illustration).
- 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, inductive heat unit (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 install the transmission housing.
- Install the transmission housing and tighten the new bolts - A, B and C - to specification.
- Install the grooved ball bearing/input shaft locking ring - 1 -.
- Remove the bracket (30-211 A) for the input shaft.
- If the retaining sleeve for the gear shift shaft was removed, then install it now all the way onto the tool. Refer to => [ Lock Sleeve Differentiation ] Transmission Housing.
- Turn the transmission so that the opening for the gear shift shaft faces up in the assembly stand.
- Install the gear shift shaft - 1 - into the lower bearing - 2 - and into the selector forks - 3 -.
• The cover - item 2 - in => [ Transmission Housing Overview ] Transmission Housing Overview 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 cover - 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 cover 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 cover - 4 -.
- Install the locking screw - 2 -, the locking pin - arrow - must not be installed when doing so.
- Install the backup lamp switch (F4) - 1 -.
- Install the input shaft seal flush.
- Install the clutch slave cylinder with release bearing. Refer to => [ Clutch Slave Cylinder with Release Bearing ] Clutch Slave Cylinder with Release Bearing.
- Move the shift lever through all the gears.
- Install the sealing cap as follows:
Sealing Cap Differentiation
- I - = Metal sealing cap, 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 will happen if the incorrect sealing cap is installed.
• For the correct sealing cap, refer to the Parts Catalog.
- Install the flange shafts with the springs, thrust washers and tapered rings.