Shift Mechanism, Input Shaft, Pinion, Cover: Overview

Internal Shift Mechanism, Input Shaft, Pinion With Hollow Shaft And Transmission Cover, Removing And Installing

Basic transmission housing disassembly and assembly: refer to "Sequence Of Operations" at Controls and Housing.

1. Transmission housing
- Removing bushing for 3rd and 4th gear shift rod: refer to "Procedures" at Housing, Input Shaft Bearing, Multi-Function Switch
- Knock in bushing with drift VW 295 and adapter tool VW 295a
Outer race for double tapered roller bearing/pinion:
- Removing: refer to "Sequence Of Operations" at Controls and Housing
- Installing: refer to "Procedures" at Housing, Input Shaft Bearing, Multi-Function Switch
Input shaft needle bearing:
- Removing: refer to "Procedures"
- Installing" refer to "Procedures"
Input shaft ball bearing:
- Removing: refer to "Sequence Of Operations" at Controls and Housing
- Installing: refer to "Sequence Of Operations" at Controls and Housing
2. Torx bolt for relay shaft
- 40 Nm (30 ft lb)
- Removing: refer to "Sequence Of Operations" at Controls and Housing
3. Spacer washer
4. Relay shaft
- Installation position: refer to "Sequence Of Operations" at Controls and Housing
- Installing: refer to "Sequence Of Operations" at Controls and Housing
5. Shift rod and shift fork for 3rd and 4th gear
- Shift rod position: refer to "Sequence Of Operations" at Controls and Housing
- Installing: refer to "Sequence Of Operations" at Controls and Housing
- Shift rod or shift fork can be replaced separately
- Removing shift rod bushing from transmission cover: refer to "Procedures"
- Removing shift rod bushing from transmission housing: refer to "Procedures" at Housing, Input Shaft Bearing, Multi-Function Switch
- Knock in with drift VW 295 and adapter tool VW 295a
- Replace shift rod bearing if worn
6. Spacer washer
7. Torx bolt for relay shaft
- 40 Nm
- Removing: refer to "Sequence of Operations" at Controls and Housing
8. Input shaft
- Removing: refer to "Sequence of Operations" at Controls and Housing
- Installing: refer to "Sequence of Operations" at Controls and Housing
- Removing bearing of input shaft from transmission housing: refer to "Sequence of Operations" at Controls and Housing
- Removing from transmission cover: refer to "Procedures"
9. Inner shift rod
- Installation position: refer to "Sequence of Operations" at Controls and Housing
- Installing: refer to "Sequence of Operations" at Controls and Housing
10. Seal for inner shift rod
- Remove with VW 681
- Knock in with VW 460/2
- Installation position: refer to "Procedures"
- With transmission installed, exhaust system and shift rod must be removed; carefully pry out seal with screwdriver and knock in with VW 423
11. Mounting bolt
- 25 Nm (18 ft lb)
12. Transmission cover
- Removing and installing oil retainer: refer to "Procedures"
- Removing bushing for 3rd and 4th gear shift rod: refer to "Procedures"
- Knock in bushing with drift VW 295 and adapter tool VW 295a
Bearing for input shaft:
- Removing: refer to "Procedures" at Housing, Input Shaft Bearing, Multi-Function Switch
- Insertion depth: refer to "Procedures" at Housing, Input Shaft Bearing, Multi-Function Switch
- Install with extractor tool 40-202
13. Pinion with hollow shaft
- Removing: refer to "Sequence of Operations" at Controls and Housing
- Installing: refer to "Sequence of Operations" at Controls and Housing
14. Shift rod with shift fork for 1st/2nd/5th and reverse gear
- Installing: refer to "Sequence of Operations" at Controls and Housing
- Installation position: refer to "Sequence of Operations" at Controls and Housing
- Remove and install spring pins for disassembling and assembling
- Removing and installing bushing for 1st and 2nd gear shift fork: refer to "Procedures"
- Shift forks for 1st and 2nd gear can be replaced separately
- Replace 5th and reverse gear shift fork only together with shift rod and carrier
15. Torx bolt
- 25 Nm (18 ft lb)
- With collar for locking spring/shift detent
16. Shift detent
- Installation position: refer to "Sequence of Operations" at Controls and Housing
- Install after inserting relay shaft -4- and inner shift rod -9-