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 37 mm Dia. (VW 416 B)
• Guide Piece (VW 436 A)
• Guide Piece (VW 439)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Guide Piece (10-15)
• Thrust Pad (3124)
• Bearing driver (3264)
• Subframe support assembling device (3290)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Drift (T10168)
• Thrust Piece (T10203)
• Drift (T10169)
• or Drift (T10362) => [ Lock Sleeve Differentiation ]
• - 1 - Kukko Extractor 14.5-18.5 mm (21/2)
• - 1 - Kukko Extractor 23.5-30 mm (21/4)
• - 4 - Kukko Support (22/2)
• Kukko Support (22/1)
1 Transmission Housing
• When replacing: Adjust output shafts and differential, refer to => [ Adjustment Overview ] Adjustment Overview
• From transmission manufacture date 10 04 6, changed in grooved ball bearing/input shaft mount area - item 3 - => [ (Item 3) Transmission Housing ]
• Refer to the Parts Catalog
2 Cover
• Removing, refer to => [ Removing the Cover ]
• Installing, refer to => [ Installing the Cover ]
3 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill
and Drain Plugs ] Service and Repair
4 Seal
• Always replace, if equipped
5 Transmission Fluid Filler Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill
and Drain Plugs ] Service and Repair
6 Locking Pin
• For adjusting the shift mechanism, refer to => [ Shift Mechanism, Adjusting ] Adjustments
• Can be replaced with transmission not disassembled
• Removing, refer to => [ Removing the Locking Elbow for the
Gearshift Shaft ]
• Installed position, refer to => [ Installed Position: Locking Elbow ]
• Installing, refer to => [ Drive Lock Elbow for Selector Shaft in up to Tool Stop. ]
7 Bushing
• For the selector rods
• Removing, refer to => [ Removing the Selector Shaft Bushing ]
• Installing, refer to => [ Installing the Selector Shaft Bushing,
to the Tool Stop ]
8 Retaining Sleeve
• Removing when the transmission is disassembled, refer to => [ Removing the Retaining Sleeve from the Transmission Housing ]
• Removing when the transmission is not disassembled, refer to => [ Removing the Retaining Sleeve on a
Transmission not Disassembled using the ]
• Different retaining sleeves, refer to => [ Lock Sleeve Differentiation ]
• Installing a retaining sleeve with a shoulder, refer to => [ Driving in Lock Sleeve with Shoulder,
to the Tool Stop ]
• Installing the retaining sleeve without a shoulder, refer to => [ Driving in Lock Sleeve without Shoulder,
to the Tool Stop ]
9 Needle Sleeve
• For the reverse shaft
• Always replace if removed
• Removing, refer to => [ Removing the Reverse Shaft Needle Sleeve
from the Transmission Housing ]
• Installing; refer to => [ Installing the Needle Sleeve into the Transmission Housing ]
10 Outer Race/Tapered Roller Bearing
• For output Shaft, 5th and 6th and reverse gear
• Removing and installing, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears
• When replacing: 5th, 6th and reverse gear output shaft, adjusting, refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting
11 Adjusting Shim
• For output Shaft, 5th and 6th and reverse gear
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview
12 Outer Race/Tapered Roller Bearing
• Output Shaft, 1st to 4th Gears
• Removing and installing
• When replacing: adjust the output shaft for 1st to 4th gear => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting
13 Adjusting Shim
• Output shaft, 1st to 4th gears
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview
14 Outer Race/Tapered Roller Bearing
• For the differential
• Removing and installing => [ Differential ] Service and Repair
• When replacing: adjusting the differential, refer to => [ Adjustment Overview ] Adjustment Overview
15 Adjusting Shim
• For the differential
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview
16 Bushing
• For the gearshift shaft
• Removing, refer to => [ Removing the Selector Shaft Bushing ]
• Installing, refer to => [ Installing the Gearshift Shaft Bearing
Bushing all the way onto the Tool ]
17 Plugs
• Removing, refer to => [ Removing the Plug ]
• Installing, refer to => [ Installing the Plug ]
18 Seal
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal
Removing the Cover - A -
- Pierce the rubber in the center of the cover with a screwdriver - B - and pry it out of the cover in direction of - arrow -.
Installing the Cover
Removing the Locking Elbow for the Gearshift Shaft
- Break off the bracket in its unlocked position.
- Insert a screwdriver - A - into the hole - B -.
- Pry out the locking elbow in direction of - arrow -.
Installed Position: Locking Elbow
- The mark on the locking elbow - arrow - must point toward the connection on the clutch slave cylinder - 1 -.
Dimension - a - must be approximately 45°.
Drive Lock Elbow - arrow - for Selector Shaft in up to Tool Stop.
• The locking bracket must be unlocked when being installed.
Removing the Selector Shaft Bushing
A Kukko extractor 14.5-18.5 mm , for example, (21/2)
B Kukko support , for example, (22/2)
Installing the Selector Shaft Bushing, to the Tool Stop
Removing the Retaining Sleeve - A - from the Transmission Housing
- Place transmission housing on (VW 401) and (VW 402) in such a way so that the alignment sleeves inside the transmission housing do not get damaged.
Removing the Retaining Sleeve on a Transmission not Disassembled using the Guide Piece (10-15)
• Locking bolt and selector shaft are removed.
- Turn the transmission so that the retaining sleeve cannot fall into the transmission.
Lock Sleeve Differentiation
The following lock sleeves may be installed:
Retaining sleeve with a shoulder - arrow 1 -, refer to => [ Driving in Lock Sleeve with Shoulder,
to the Tool Stop ].
Retaining sleeve without a shoulder - arrow 2 -, refer to => [ Driving in Lock Sleeve without Shoulder,
to the Tool Stop ].
Refer to the Parts Catalog.
Driving in Lock Sleeve with Shoulder, to the Tool Stop
• The transmission housing is bolted to the clutch housing.
Driving in Lock Sleeve without Shoulder, to the Tool Stop
• The transmission housing is bolted to the clutch housing.
Removing the Reverse Shaft Needle Sleeve from the Transmission Housing
A Kukko extractor 23.5-30 mm , for example, (21/4)
B Kukko support , for example, (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 shaft thrust washer - B - on the needle sleeve while pressing it in.
- Support transmission housing beneath bearing mount using (VW 416 B).
Removing the Selector Shaft Bushing
- Use the thread adapter from the (22/1) - arrow -.
- Hold the spindle on the (3290) and turn the nut - B -.
A Kukko extractor 14.5-18.5 mm , for example, (21/2)
Installing the Gearshift Shaft Bearing Bushing - A - all the way onto the Tool
Removing the Plug - 1 -
- Remove the plug - 1 - from the inside of the transmission housing toward the outside - arrow -.
Installing the Plug - 1 -
- Using (3264) , drive in sealing plugs to dimension - a - approximately 3 mm below upper edge of housing.