Transmission
Transmission
=> [ Disassembly ]
=> [ Assembly ]
• Metal and plastic sealing caps are installed for the input shaft.
The lock ring - A - has been discontinued together with the plastic sealing cap for the input shaft.
• - I - = Steel sealing cap for the input shaft with a lock ring - A -
• - II - = Plastic sealing cap for the input shaft without a lock ring
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 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) or Press Tool for Shaft Piece (T10180)
• Drift (T10169) or (T10362)
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Hot Air Blower (V.A.G 1416)
• Drip Tray for VAS 6100 (VAS 6208)
• Sealing Paste (AMV 188 200 03)
Disassembly
- Attach the transmission to the assembly stand with the bolts - arrows -.
• If one of the bolt holes does not touch the transmission support place shims between the hole and the transmission support.
- Turn the transmission and the assembly stand until the drain plug is facing down.
- Place the 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 blocked by the lock pin - arrow -.
- Move the gear shift shaft into neutral.
- Remove the backup lamp switch - 1 -.
- Remove the locking screw - 2 -.
- Then remove the bolts - 3 -.
- Remove the gear shift unit - 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 may have different lengths.
- 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, the 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 lock ring - A -.
- Pierce the rubber cover - C - in the center using a screwdriver.
- Remove the cover 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)
• You can push through the sealing cap in order to remove the cap - 1 -
• Pry the sealing cap - 1 - carefully out of the transmission housing.
Plastic Sealing Cap
Carefully remove all the tabs - A -. Do not damage the transmission housing when doing so.
- Remove the sealing cap - A -.
• Make sure the broken pieces of the sealing cap are removed, as necessary.
Continuation for All
Remove the lock ring - C - from the grooved ball bearing on the input shaft/transmission housing as follows:
- Hold one end of the lock ring secure with a screwdriver - A -.
- Pry the other end of the lock ring out of the groove in the grooved ball bearing in the - direction of the arrow - using another screwdriver - B -.
- Pry out the rest of the lock ring using the screwdriver - B -.
- Remove the bolts - A - that attach the transmission housing to the clutch housing.
- Install adapter for VW 771 slide hammer (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, the hot air blower (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 alternating 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 gears together with the selector shafts - 2 - - arrow A -.
- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th, 6th and reverse gears - 3 - together with the selector shafts out of the clutch housing - arrow B -.
• If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.
- Remove the input shaft seal.
• Always replace the grooved ball bearing (- item 4 - in the => [ Input Shaft Overview ] Input Shaft Overview) on the input shaft.
Assembly
• Press the new grooved ball bearing (- item 4 - in the => [ 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, 6th gear selector shaft - 2 -.
- Install the input shaft - 1 -, the 5th, 6th gear output shaft - 2 - and the 5th, 6th gear selector shaft - 3 -, the reverse gear selector fork - 4 - and the 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 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 gears output shaft - 3 - with the selector shafts - 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 selector shaft - 2 - together with the reverse gear shaft slightly at the same time.
- Install the 1st through 4th gears 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 bearing seats with help of a second technician.
- Secure 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 dot.
- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see the next graphic).
- 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 with a heat gun, for example, the hot air blower (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 mount 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 lock 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, refer to => [ Locking 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 sealing cap 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 unit - 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 unit 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 unit - 4 -.
- Install the locking screw - 2 -, the locking pin - arrow - must not be installed when doing so.
- Install the backup lamp switch - 1 -.
- Install the input shaft seal so that it is flush.
- Install the clutch slave cylinder with release bearing. Refer to => [ Clutch Slave Cylinder with Release Bearing ] Service and Repair.
- Move the shift lever through all the gears.
- Install the sealing cap as follows:
Sealing Cap Differentiation
- I - = Metal sealing cap with a lock ring - A -.
- II - = Plastic sealing cap without a lock ring.
Allocation
Metal Sealing Cap
- Install the sealing cap all the way into the transmission housing.
- Secure the sealing cap with the lock ring - A -.
Plastic Sealing
- Install the sealing cap all the way into the transmission housing using the press tool for shaft seal (T10180).
Continuation for All
• Always pay attention to the sealing cap allocation. Refer to => [ Allocation ].
• Leaks in the case are caused by an incorrect installation.
• For the correct sealing cap, refer to the Parts Catalog.
- Install the flange shafts with the springs, thrust washers and tapered rings.