Transmission, Disassembly
Transmission, Disassembly
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Thrust Tube (VW 455)
• Slide Hammer-Complete Set (VW 771)
• Adapter (VW 771/44)
• Support Bridge (T10323)
• Socket and Extended Bit (T10107 A)
• Counter-Hold Tool (3435)
• Thrust Piece (T10042)
• Counter Hold Tool (T10371)
• Thrust Piece (T10233)
• Heat Gun (V.A.G 1416)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Separating Tool 5-60 mm (17/0)
• Kukko Support (22/1)
• Front and Rear Bearing Tool (3348/2)
• Sealing Paste (AMV 188 200 03)
• Universal Grease (G 060 735 A2)
Disassembly
- Install the transmission to the transmission support (VW 353) with the bolts - arrows -.
- Use holes - 1 and 2 -.
- Remove the clutch slave cylinder with release bearing bolts - arrows A - and slave cylinder.
- Remove the bolt - arrow B - for the right stub shaft.
- Remove the stub shaft.
- Place a drip tray under the transmission.
- Drain the transmission fluid.
- Remove the clutch housing to transmission housing bolts.
- Install the thrust tube (VW 455) over the input shaft on the clutch housing and secure the input shaft - B -.
- Install a separating tool 5-60 mm - A -, for example (17/0) , tightly behind the input shaft splines.
• The back of the separating tool must touch the thrust tube free-of-play.
- Move the shift unit selector shaft into the neutral position.
Ignore the - arrow -.
- Remove the backup lamp switch (F4) - A -.
- Remove the shift unit - B - bolts.
- Remove the shift unit from the transmission housing; while doing this, rotate the shift unit 180° when removing it.
• The shift unit shift fingers must be guided through the selector rods.
- Remove the nuts - C -.
- Remove the trip recorder sensor (G75) - A - bolt - arrow - and sensor, if equipped.
- Remove the screws and the retainer plate - 1 -.
- Or, remove the stud bolt - arrow - and retaining bracket - 2 -.
- Push through the center of the sealing cap - C - using a screwdriver.
- Pry the sealing cap out of the transmission housing.
- If necessary, pull the cap off the transmission housing.
A Support , for example (22/1)
B Extractor 14.5-18.5 mm, for example (21/2)
Remove the locking ring - C - from the input shaft grooved ball bearing as follows:
- Hold one end of the locking ring with a screwdriver - A -.
- Pry the other end of the locking ring out of the groove in the grooved ball bearing - arrow - with a second screwdriver - B -.
- Reposition the screwdriver - B - and pry the locking ring out further.
- Counter hold the stub shaft using the counter hold tool (T10371) and remove the bolt for the left stub shaft - A -.
- Remove the stub shaft.
- Remove the transmission housing to clutch housing bolts.
• If the bolts - B - are present, then these do not need to be removed in order to remove the transmission housing.
- Install the adapter (VW 771/44) all the way into the threaded bore in the transmission housing and secure it with the nut - A -.
- 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, (V.A.G 1416).
- Separate the transmission housing from the clutch housing using the slide hammer (VW 771) and the adapter (VW 771/44). At the same time separate the transmission housing on the housing brace - arrow - from the clutch housing with a pry bar - B -.
- Remove the separating tool - A - and the thrust tube (VW 455) from the input shaft - B -.
- Remove the reverse gear selector fork - A -.
- Carefully bring the transmission into a slightly angled position, if necessary.
- Lift the input shaft - 1 - in the - direction of the arrow - just enough until it is possible to insert the counter-hold tool (3435).
- Rotate the transmission back into its original horizontal position.
- Attach the stub shaft - 1 - to the differential; this way the differential can be raised in the following work steps.
- Remove the 3rd and 4th gear output shaft - 2 - together with the selector shaft with selector fork - 3 -.
- Carefully bring the transmission into a slightly angled position.
- Push the 1st and 2nd gear output shaft - B - all the way up.
- Then remove the reverse gear output shaft - A -.
When the transmission is in an angled position, components of the transmission could come loose.
To prevent this, move the transmission back into its original horizontal position.
- Then remove the 1st and 2nd gear output shaft - B - together with the selector shaft with selector rod - C - from the clutch housing.
- Remove the input shaft - 1 - together with the selector shaft with selector rod - 2 -.
- Remove the differential - 3 - from the stub shaft.
- Remove the input shaft seal.
• Always replace the grooved ball bearing - item 16 - in => [ Input Shaft Overview ] Input Shaft Overview on the input shaft.