Transmission Housing
Transmission Housing
Special tools, testers and auxiliary items required
• Drift (VW 295)
• Adapter (VW 295 A)
• Tube (VW 423)
• Slide Hammer-Complete Set (VW 771)
• Holding plate (VW 801)
• Guide pin (10 - 15)
• Seal driver-front wheel bearing (30 - 100)
• Driving sleeve (32 - 109)
• Lock pin (2064)
• Alignment fixture (3253)
• Internal puller (3275)
• Internal extractor (Kukko 21/2)
• Support (Kukko 22/1)
• Support (Kukko 22/2)
• Depth gauge
• Straight-edge (T 40100)
Remove input shaft needle bearing from transmission housing
A Support, e.g. ( Kukko 22/2)
- Remove peening indentations, if present.
Drive input shaft needle bearing into transmission housing
Install needle bearing with lettering on bearing (the side with thicker metal) facing towards sleeve (30 - 100).
Needle bearing drive-in depth, refer to => [ Measure needle bearing drive-in depth and secure needle bearing with peening ]
Measure needle bearing drive-in depth and secure needle bearing with peening
• Drive-in dimension - a - = 88.0 ± 0.5 mm
- To peen, use blunt center punch with ball-shaped end (ball dia. 5 mm).
- Needle bearing is secured with three peening marks on circumference every 120 degrees - arrows -.
Remove selector shaft ball sleeve
A Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
- Remove peening indentations, if present.
Drive on selector shaft ball sleeve and secure with peening
Set ball sleeve in place with inscribed side (thicker wall) facing toward guide pin (10 - 15).
- Drive in ball sleeve - 1 - to installation dimension - a - = 1.5 ± 0.5 mm below housing surface.
After driving on, secure ball sleeve with peening as follows:
- To peen, use blunt center punch with ball-shaped end.
- Secure ball sleeve with 3 peening marks - b - on circumference spaced every 120°.
Breather tube installation dimension
Dimension - a - = 16.8 mm
Selector shaft sealing ring, removing from disassembled transmission
- Carefully pry off sealing ring without damaging shaft.
Selector shaft sealing ring, removing from assembled transmission
- Carefully pry out seal using a screwdriver.
Remove selector shaft ball sleeve
Remove selector shaft sealing ring first, refer to => [ Selector shaft sealing ring, removing from disassembled transmission ]
A Support, e.g. ( Kukko 22/1)
B Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
Selector shaft ball sleeve, driving on
• Drive-in depth: 8.5 ± 0.5 mm below housing surface.
Driving in selector shaft seal
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Lightly oil outer circumference of seal.
- Drive sealing ring - arrow - in 1.0 ± 0.2 mm below housing surface, do not tilt when doing so.
Input shaft grooved ball bearing, removing from disassembled transmission
- Place adapter (VW 295 A) with small dia. in grooved ball bearing.
- Drive out grooved ball bearing.
Drive input shaft grooved ball bearing in to stop
Installation position:
Closed side of cage for balls points toward transmission housing.
- Drive grooved ball bearing in transmission housing to stop.
Remove selector rod ball sleeve - C -
A Support, e.g. ( Kukko 22/2)
B Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
Drive in selector rod ball sleeve
- Drive in ball sleeve - A - for 5th/6th gear selector rod with lock pin (2064) to installation dimension, refer to => [ Drive-in depth for ball sleeves in transmission housing ]
- Drive in remaining 3 ball sleeves - B - with guide pin (10 - 15) to installation dimension, refer to => [ Drive-in depth for ball sleeves in transmission housing ]
Insert bearing sleeve in inscribed side (greater thickness) facing toward guide pin (10 - 15) or lock pin (2064).
Drive-in depth for ball sleeves in transmission housing
- Drive in 5th/6th gear selector rod ball sleeve - 1 - to dimension - a - = 143.5 ± 0.5 mm.
- Drive in 5th/6th gear selector rod ball sleeve - 2 - to dimension - a - = 133.5 ± 0.5 mm.
- Drive in 1st/2nd gear selector rod ball sleeve - 3 - to dimension - a - = 116.5 ± 0.5 mm.
- Drive in ball sleeve for reverse gear selector rod - 4 - to dimension - a - = 116.5 ± 0.5 mm.
• Measure with a depth gauge from housing joint surface to respective ball sleeve.