Assembly Sequence

Assembly sequence
Disassembling and assembling transmission housing, selector mechanism, input shaft, output shafts, differential and selector rods





Special tools and equipment
^ VW 309 Holding plate
^ VW 313 Support clamp
^ VW 353 transmission support
^ 30-21 Sleeve
^ T40008 Press piece

Disassembling





^ Secure transmission to assembly support with bolts -arrows-.
^ Turn transmission on assembly support with oil drain plug downward.
^ Place drip tray underneath.
^ Drain transmission oil.





^ Remove slave cylinder with release bearing -arrows-.
^ Put selector shaft in neutral position.





^ Remove back-up light switch -1-.
^ Remove hex bolts -2- for selector shaft cover plate -A-.
^ Carefully pull out cover plate.
^ Remove locking bolt -3- for selector shaft gate.
^ Remove bolts -4- and press selector shaft cover -B- out of transmission housing.
^ Pull selector shaft out of transmission housing.
^ Remove both flange shafts.





^ Remove bolts securing transmission housing to clutch housing -A- in area of differential.





^ Remove bolts -B- inside clutch housing for securing clutch housing to transmission housing.

Note: The hex bolt -arrow- is located outside the bolting flange. It is fitted with a washer.

^ Take off transmission housing. If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.





^ Swing input shaft in direction of arrow and take off.
^ Remove speedometer drive.





^ With help of a second mechanic, remove differential -1-, output shafts -2- and -3-, reverse shaft -4- and selector rods -5- together from clutch housing.
^ Drive out input shaft oil seal with sleeve 30-21.

Assembling
^ Install differential -1-.
^ Install 5th, 6th and reverse gear output shaft -2- together with reverse selector fork, 5th, 6th and reverse gear selector rod -3- and reverse shaft -4-.





^ Take 1st-4th gear output shaft -3- with selector rods -5- in right hand as illustrated.
^ With left hand, lift differential slightly.
^ At same time, have a second mechanic slightly lift 5th, 6th and reverse gear output shaft together with reverse shaft -4-.
^ Insert 1st-4th gear output shaft in direction of arrow.
Toothing of output shafts and final drive gear/differential must mesh.
^ Together with second mechanic, place shafts in their bearing seats.





^ Set input shaft in clutch housing and swing in -arrow-.
^ Fit transmission housing.
Install selector shaft as follows:
^ Bring selector rods -A- into neutral.








^ Insert selector shaft -1-.
^ Position selector shaft so that shift fingers are inserted in selector rods
^ Refer to Input Shaft, Output Shafts (Pinion Shafts), Differential and Selector Rods, Disassembling and Assembling, See Fig. 2.
^ When doing this, align lower selector shaft bearing -arrow- through drilling for cover plate.
^ Bolt cover plate -A- to lower selector shaft bearing -1- with bolt -2-, M8 x 60 mm.





^ Hand tighten cover plate -A- by alternately tightening (1/2 turn) bolts -arrows-.
^ Remove bolt -2- and hand tighten original bolt in its place.
^ Install selector shaft cover -B- and tighten hex bolts to torque.
^ Tighten cover plate hex bolts.
^ Insert locking bolt -3- for selector shaft gate with locking fluid D 000 600 A2.
^ Install switch for back-up light.
^ Install flange shafts with springs, thrust washers and tapered rings.
^ Install speedometer sender.





^ Press in input shaft oil seal.
^ Install slave cylinder with release bearing.