Transmission, With a Sealing Cap Circlip For the Input Shaft
Transmission, with a Sealing Cap Circlip for the Input Shaft
=> [ Disassembly ]
=> [ Assembly ]
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Tube (VW 455)
• or Sleeve (3160)
• Slide Hammer-Complete Set (VW 771)
• Kukko Internal Puller (21/01)
• Kukko Separating Tool 5-60 mm (17/0)
• Kukko Support (22/1)
• Adapter (VW 771/40)
• Extractor Lever (VW 681)
• Support Bridge (30-211A)
• Thrust Piece (T10042)
• Thrust Piece (T10143)
• Thrust Piece (T40008)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Hot Air Blower (V.A.G 1416)
• Or Drift (T10169)
• Socket and Extended Bit (T10107)
• Sleeve (3160)
• Extractor Lever (VW 681)
• Bracket (30-211A)
• Drift (T10362) => [ Lock Sleeve Differentiation ] Transmission Housing, Servicing
Disassembly
Perform the following work:
- Attach the transmission to the assembly stand with bolts - arrows -.
• If one of the fastening holes does not touch the (VW 353) place shims between the hole and the (VW 353).
- Turn the transmission assembly stand with the oil drain plug facing down.
- Place a drip tray underneath.
- Drain gear oil from manual transmission.
Transmission
- Remove right flange shaft countersunk bolt with (T10107).
- Remove the 4 bolts - arrows - (only 3 bolts are shown in the illustration) connecting the bevel box to the manual transmission.
- Carefully press bevel box off manual transmission while protecting it against falling through.
- Remove the slave cylinder with the release bearing - arrows -.
- 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.
The stub shaft splines on the input shaft has different lengths on the transmission.
- Either place the (VW 455) over the input shaft on the clutch housing.
- Or place the (3160) over the input shaft on the clutch housing.
- Tension the separating tool - A -, for example (17/0) , tightly behind the splines on the input shaft.
The back of the separating tool must touch the (VW 455) or the (3160) free-of-play.
- Remove the left flange shaft.
Make sure the gearshift shaft is not blocked by the lock elbow - arrow -.
- Move the gearshift shaft into neutral.
- Remove the locking bolt - 2 -.
- Then remove the bolts - 3 -.
- Remove the back-up lamp switch (F4) - 1 -.
- Remove the gearshift shaft - 4 - from the transmission housing.
- Remove the cap/input shaft circlip - A -.
- Pierce the rubber piece into the center of the cover - C - using a screwdriver.
- Remove the cover from the transmission housing.
A Kukko support , for example, (22/1)
B Kukko internal puller 8 to 12 mm , for example, (21/01)
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 the screwdrivers - A -.
- Pry the other end out of the groove in the grooved ball bearing in direction of - arrow - using the 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 (VW 771/40) into the threaded hole in the transmission housing.
- Heat transmission housing using, for example, the (V.A.G 1416) , in area of bearing seat for grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.
- Remove the transmission housing from the clutch housing in direction of - arrow - using slide hammer (VW 771/1).
• Pry out carefully with a pry lever all around the housing braces alternation from side to side. Be careful not to damage the sealing surfaces.
- Remove the separating tool - A - and the (VW 455) or the (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 shift rods - 2 - - arrow A -.
- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear - 3 - together with the selector rods out of the clutch housing - arrow B -.
• If necessary, differential can be shifted again in clutch housing after lifting shafts.
- Pry out the input shaft seal using the (VW 681).
• Always replace the grooved ball bearing on the input shaft. Refer to - 6 - => [ (Item 6) Grooved Ball Bearing ]
Assembly
• Press the new grooved ball bearing onto the input shaft - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
Perform the following work:
- Install the input shaft - 1 -, output shaft 5th/6th gears - 2 - with the selector shaft - 3 -, reverse gear shift fork - 4 - and reverse shaft - 5 -.
Pay attention to the different bearing for the reverse gear shift fork.
The reverse gear selector fork - 1 - is mounted on the axle - 2 - behind the 5th and 6th gear selector shaft- 3 -.
Reverse gear selector fork - 1 - mounted on the selector shaft with the 5th and 6th gear selector fork - 2 -.
Continuation for All
- Install the differential - 1 -.
• A 2nd technician is needed to help install the shafts into the clutch housing.
- Hold 1st through 4th gear output shaft - 3 - with the gearshift rods - 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 and reverse gear - 2 - together with the reverse shaft slightly at the same time.
- Install the 1st through 4th gear output shaft in direction of - arrow -.
• Places of the input shaft, output shafts and final drive gear/differential must engage.
- Install the shafts and the differential in their bearing seats with the help of a second technician.
- Secure the (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.
• If the flat sides - A and B - are present, do not insert any washers above and below the grooved ball bearing.
• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.
- Mark the flat side in color.
- Transfer the markings to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see next figure).
- Heat transmission housing using (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to 100 °C (212 °F) for approximately 10 minutes.
• 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 marking on the grooved ball bearing - A - with the marking on the transmission housing - B - and mount the transmission housing.
- Install the transmission housing and tighten the new bolts - A -, - B and C - to the tightening specification.
Allocation of bolts:
A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer
- Install the grooved ball bearing/input shaft locking ring - 1 -.
- Attach the (30 - 211 A) for the input shaft.
- If the retaining sleeve for the shift shaft was removed, then install it now all the way onto the tool, refer to => [ Lock Sleeve Differentiation ] Transmission Housing, Servicing.
- Turn the transmission so that the opening for the gearshift shaft faces up in the assembly stand.
- Install the gearshift shaft - 1 - into the lower bearing - 2 - and into the shift forks - 3 -.
• The cover is not shown in the illustration.
- Push the shift shaft - 1 - against the retaining sleeve - 2 - in direction of - arrow - and guide it through the shift fork all the way down using the shift finger - 3 -.
• The shift cover - 4 - must stand parallel to the bolting surface on the transmission housing.
• It must be possible to move the shift shaft easily (forward and backward).
• If the shift cover is at an angle to the bolting surface, then the shift shaft is not installed into the lower bearing.
- Tighten the bolts - 3 - for the shift cover - 4 -.
- Install the locking bolt - 2 -, lock elbow - arrow - must not be installed when doing so.
- Install the back-up lamp switch (F4) - 1 -.
- Install the input shaft seal so that it is flush.
- Install slave cylinder with release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder With Release Bearing.
- Move the shift lever (selector lever) through all the gears.
- Install the cap all the way into the transmission housing.
- Secure the cap with the locking ring - A -.
- Install the flange shafts with the springs, thrust washers and tapered rings.
Install the bevel box into the manual transmission as follows:
- Lubricate the splines on the differential with grease for clutch disc shaft splines (G 000 100) on the manual transmission.
- Slide on bevel box completely on manual transmission, while doing this, join splines of input shaft/bevel box centrally with differential.
- Line up the splines on the right flange shaft with the differential bevel gear. Turn the flange shaft if necessary.
- With proper tooth position and central guiding, bevel box slips up to stop against manual transmission.
• Do not pull bevel box with mounting bolts against manual transmission, otherwise bevel box is canted and mounting eyelets can break off.
- Install the 4 bolts - arrows - (only 3 bolts are shown in the illustration) connecting the bevel box to the manual transmission.
- Tighten the right flange shaft conical head bolt with the (T10107).