Removing

Bearing housing, Torsen differential, end cover, internal selector mechanism, input shaft, drive pinion and hollow shaft, removing and installing (assembly sequence)

Special tools, testers and auxiliary items required:
Engine and transmission support VW 540
^ Drip tray V.A.G 1306
^ Multi-purpose tool 771/1 with attachments 771/15, 771/37 and stud Me/ M10
^ Two-arm puller e.g. Kukko 20/10 with 200 mm long hooks
^ Mandrel 2064
^ Clamping sleeve 3116
^ Thrust piece 3118
^ Drift3121
^ Internal puller 3275
^ Pressing tool 3276
^ Thrust plate VW 402
^ Press tool VW 407
^ Press tool VW 412
^ Tube VW 415a
^ Thrust plate VW 447h
^ Thrust pad VW 454
^ Extractor lever VW 681
^ Extension piece 30-23
^ Drift sleeve 30-100
^ Support bridge 30-211A
^ Press tool 40-21
^ Depth gauge

Removing





- Secure transmission on engine and transmission support VW 540.
- Place drip tray V.A.G 1306 underneath and drain transmission oil (2 oil drain plugs).
- Remove release bearing, clutch release lever and guide sleeve, Refer to Clutch MT, Service and Repair





- Remove bearing housing (arrow) and pull off.
M8/M10 stud





- When pulling off, bearing housing is pressed slightly off end cover by spring -A-.
- Note position of spring plate -C when removing bearing housing.
^ Outer diameter (concave side) towards shims
- Remove shims -B-, note thickness redetermine if necessary, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)





- Pull Torsen differential out of end cover.





- Pull oil collector out of end cover (arrow) until it moves freely.





- Swing oil collector (arrow) down and guide out through hole in end cover.
- Remove oil collector.





- Remove locking bolts -A- for selector shaft from transmission housing.
- Mark installation positions of aluminum bolts and steel bolts; do not interchange.
- Remove 3 bolts -B- for cover for selector shaft, take off cover.
- Pull out selector shaft.





- Lock input shaft by engaging 2 gears (e.g. reverse and 2nd gear) do this by moving 2 selector plates (arrows).





- Loosen and unscrew multi-point socket head bolt (arrow-Be) in input shaft through hole (arrow -A-) in end cover.
- Remove 2 securing bolts (arrow -C-) for end cover for transmission at supporting plate for needle bearings -arrow D-.
- Take out supporting plate.





- Remove 2 magnets (arrows -A-) and clean.
- Loosen 5 bolts (arrows -B-) for securing end cover for transmission and remove.





- Pull 2nd inner race for ball bearing for input shaft from input shaft.
A - Washer

Note: The internal extractor 3275 grips the circumferential groove of the inner race (arrow) during the pulling operation.

- Take off end cover together with end cover/bearing plate gasket.
- Pull dowel sleeves out of bearing plate.





- Pull off 5th speed sliding gear with spring together with 1st inner race -A for ball bearing for input shaft.
B - Two arm puller, e.g. Kukko 20/10
- Take off 5th gear synchro-ring.
- Take off circlip for 5th speed gear.





- Pull off 5th speed gear, to do this, block hollow shaft by engaging 2 gears, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)

Note: Use only hex bolt of tensioning sleeve 31 16, length 50 mm.

C - Two arm puller, e.g. Kukko 20/10 with 200 mm long puller arms
- Remove shim -B- for 5th speed gear, note thickness and re-determine if necessary Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
- Take off spacer sleeve -A-.





- Press out roll pin -A- for selector fork for 5th and 6th gear.

Note: Do not drive out roll pin, otherwise selector rod bearing will be damaged.

- Pull selector rod on follower together with selector fork for 5th and 6th gear and locking collar as far as possible away from bearing plate (until stop is felt).





- Mark installation position (arrow-3-) of locking collar for 5th and 6th gear (arrow -1-) and synchro-hub -A- (paired).





- Pull follower together with selector fork and locking collar off selector rod.





- Pull off 6th speed sliding gear, synchro-ring for 6th gear, synchrohub for 5th and 6th speed gears and inner race for 5th speed sliding gear.
A - Two arm puller, e.g. Kukko 20/10 with 200 mm long hooks





Unscrew selector rod locking bolts.
A - 1st and 2nd gear
B - 3rd and 4th gear
C - 5th and 6th gear
D - Reverse gear
- Mark fitting locations of aluminum and steel bolts. (Bolts must not be interchanged when installing.)
- Drive out dowel sleeves on bearing plate and remove bearing plate from transmission housing.
- Secure drive pinion relative to hollow shaft e.g. hose tie, to prevent it falling out.
- Separate bearing plate with input shaft, with drive pinion and hollow shaft and with inner selector mechanism from transmission housing.





- Remove circlip from selector rod for 1st and 2nd gear and take off follower -A-.
- Pull out selector rod -B- for 5th and 6th gear.
- Remove follower -C- for reverse gear.





- Pull thrust washer (arrow -A-) for needle bearing for 6th gear off shaft.
- Use right-angled circlip pliers to remove circlip (arrow -B-) for inner race for cylinder roller bearing.
- Take out inner race (arrow -C-) for cylinder roller bearing (not a press fit).





- Take input shaft -A- with selector rod and selector fork for 3rd and 4th gear out at an angle from bearing plate.





- Unscrew hex bolt -D-, take off spring clasp -B- and retaining plate -A-, pull out shaft -C- for reverse idler gear.
- Take out spring, synchro-ring and reverse idler gear.
- Take off relay lever for reverse gear.
Removing and installing reverse gear, Refer to Bearing Plate, Servicing

Note:
^ Drive pinion and hollow shaft can be removed complete if the 6th speed gear can be easily pried off.
^ If it is necessary to press off the 6th speed gear, the drive pinion must be pulled out of the hollow shaft.

- Remove drive pinion circlip.





- Pull drive pinion out of hollow shaft -D-, when doing this catch tapered rollers -A-(Qty. 23).
- Take off corrugated spring -B- and needle ring -C-.

Note: Carefully protect bearings from dirt, clean if necessary.





- Check bearing to ensure it is complete:
1. Flange ring (tapered contact surface to tapered rollers)
2. Tapered rollers (Qty. 23) with larger diameter facing towards drive pinion head
3. Support ring (tapered contact surface to tapered rollers)
4. Corrugated spring
5. Circlip for tapered roller bearing for drive pinion





- Press off 6th speed gear.

Note: Because of the type of fit, it may be possible to press gear off easily.

- Take hollow shaft or drive pinion and hollow shaft with selector rod and selector fork for 1st and 2nd gear out of bearing plate.