Transmission, Without a Sealing Cap Circlip For the Input Shaft
Transmission, without 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)
• Extractor Lever (VW 681)
• Bracket (30-211A)
• Thrust Piece (T10042)
• Thrust Piece (T40008)
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Hot Air Blower (V.A.G 1416)
• Or Drift (T10169)
• Drift (T10362) => [ Lock Sleeve Differentiation ] Transmission Housing, Servicing
• Bracket (30 - 211 A)
• Socket and Extended Bit (T10107)
Disassembly
- 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, the assembly stand with the oil drain plug facing down.
- Place a drip tray underneath.
- Drain gear oil from the manual transmission.
- Remove the right flange shaft or the stub shaft (the illustrations shows the left flange shaft)
From transmission manufacture date 11/1/04, the right stub shaft was replaced by a flange shaft.
For the correct allocation, refer to the Parts Catalog.
- 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 Kukko 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.
- Transmission for vehicles with start/stop system: Remove the transmission neutral position sensor (G701) - arrow -.
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.
- 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 screwdriver - 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 washer - 1 - from the transmission housing - 2 -, if equipped.
• If the transmission is replaced, see if the washer must be installed..
- 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 transmission housing using (V.A.G 1416) in the area of the bearing seat for grooved ball bearing/input shaft to 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 washer - 1 - from the grooved ball bearing - 2 -, if equipped.
- If transmission is replaced, see if the washer must be installed..
- 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.
- Remove the input shaft seal using the sleeve (30-21).
• Always replace the grooved ball bearing on the input shaft. Refer to - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
Assembly
• Press the new grooved ball bearing onto the input shaft - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
- Install the input shaft - 1 -, output shaft 5th/6th gear - 2 - together with the shift rods - 3 -, the shift fork - 4 - and the reverse shaft - 5 -.
- 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 selector rods - 4 - in the right hand as illustrated.
- Slightly lift the differential 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 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.
With some transmissions, there are flattened sides - A - on the input shaft grooved ball bearing and on the bearing mount - B -.
Check the grooved ball bearing for the input shaft and the transmission housing.
From transmission build date 4.10.06 through approximately 1.21.08
One washer each is inserted above and below the input shaft grooved ball bearing - item 6 - => [ (Item 6) Grooved Ball Bearing ] .
Measuring the Offset above the Mount for the Grooved Ball Bearing
The Area under the Grooved Ball Bearing Seat in the Transmission Housing has been Changed - arrow -.
- Place a shim (outer circumference = 85 mm) - 1 - on the grooved ball bearing - 2 -, if necessary.
On Some Transmissions
Flattened Areas - A - on the Input Shaft Grooved Ball Bearing and Bearing Mount - B -.
• Do not place 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.
• Align the marking on the grooved ball bearing - A - with the marking on the transmission housing - B - and mount the transmission housing.
- Heat the transmission housing with (V.A.G 1416) in the grooved ball bearing/input shaft bearing set area to 100 °C (212 °F) for approximately 10 minutes.
- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch 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
- If a shim was placed on the grooved ball bearing prior to installing the transmission housing, then it is necessary to place a shim - 1 - (outer circumference = 78.6 mm) after installing the transmission housing - 2 -.
- Install the grooved ball bearing/input shaft locking ring - 1 -.
- Remove the (30 - 211 A) for the input shaft.
- If the retaining sleeve for the gearshift 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 gearshift shaft - 1 - against the retaining sleeve - 2 - in direction of - arrow - and guide is through the shift fork all the way down using the shift finger - 3 -.
• The gearshift cover - 4 - must stand parallel to the bolting surface on the transmission housing.
• It must be possible to move the gearshift shaft easily (forward and backward).
• If the gearshift cover is at an angle to the bolting surface, then the gearshift shaft is not installed into the lower bearing.
- Tighten the bolts - 3 - for the gearshift 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 gearshift lever (selector lever) through all the gears.
- Install the cap all the way into the transmission housing.
- Install the flange shaft and stub shaft, the pressure springs, the thrust washers and the tapered rings.
From transmission manufacture date 11/1/04, the right stub shaft was replaced by a flange shaft.
Allocation, refer to the Parts Catalog.