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 Assm. Device (3290)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Drift (T10168)
• Drift (T10169) or (T10362)
• 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 Cover
- Pierce the center of the rubber cover - A - with a screwdriver - B - and pry out the cover in the - direction of arrow -.
Installing the Cover
Removing the Locking Pin for the Gear Shift Shaft
- Break off the bracket in its unlocked position.
- Insert a screwdriver - A - into the hole in the locking bracket - 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°.
Driving the Locking Pin for the Gear Shift Shaft In up to the Tool Stop
• The locking pin - arrow - 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 as Far as the Stop on the Tool
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 from an Assembled Transmission using the Guide Piece (10-15)
• Locking pin and selector shaft removed.
- Turn the transmission so that the retaining sleeve cannot fall into the transmission.
Lock Sleeve Differentiation
The following lock sleeves may be installed:
Lock sleeve with a shoulder - arrow 1 -, refer to => [ Driving in the Locking Sleeve with a Shoulder as Far as the Stop on the Tool ].
Lock sleeve without a shoulder - arrow 2 -, refer to => [ Driving in the Locking Sleeve without a Shoulder as Far as the Stop on the Tool ].
Refer to the Parts Catalog.
Driving in the Locking Sleeve with a Shoulder as Far as the Stop on the Tool
• The transmission housing is bolted to the clutch housing.
Driving 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 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 it must be replaced.
Installing the Needle Sleeve into the Transmission Housing
- Lay the reverse shaft thrust washer - B - on the needle sleeve - A - 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 - as Far as the Stop on the Tool
Removing the Plug
- Remove the plug - 1 - from the inside of the transmission housing to the outside.
Installing the Plug
- Install the plug - 1 - approximately 3 mm under the upper edge of the housing - a - using the bearing driver (3264).