Transmission Housing, Servicing
Transmission housing, servicing - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items required:
^ Multi-purpose tool 771/1 with attachment 771/15
^ Mandrel 2062
^ Press tool VW 408 A
^ Tube VW 423
^ Thrust pad VW 454
^ Extractor lever VW 681
^ Guide pin 10-15
^ Drift sleeve 30-100
^ Mandrel 30-505
^ Installing tool 40-503
^ Internal puller 14.5-18.5 mm e.g. Kukko 21/2
^ Internal puller 30-37 mm e.g. Kukko 21/5
^ Depth gauge
^ Assembly sleeve, Part No. 01E 311 120
Note:
^ Refer to general repair instructions
^ Adjustments are required when replacing components marked 1).
1 - Seal
^ For drive flange
^ Fill space between sealing lips with sealing grease G52 128 A1.
^ Replace with transmission installed
2 - Final drive cover 1)
3 - O-ring
^ For cover for final drive
^ Always replace
4 - Shim "S1"
^ Note thickness
^ Adjustment overview
5 - Outer race for large tapered roller bearing 1)
^ For differential
6 - Outer race for small tapered roller bearing 1)
^ For differential
7 - Shim "S2"
^ Note thickness
^ Adjustment overview
8 - Seal
^ For input shaft
^ Always replace when removing input shaft
^ Replace when transmission is not disassembled
9 - Oil drain plug, 40 Nm
10 - Ball sleeve
^ For selector shaft
^ Replace
11 - Ball sleeves
^ For selector shafts
^ Replace
12 - Circlip
^ Installation position: eyes facing up
13 - Switch for back-up lights, 20 Nm
14 - O-ring
^ For cover for selector shaft
^ Always replace
15 - Cover for selector shaft
16 - Ball stud, 20 Nm
^ For connecting rod
17 - Outer race for large tapered roller bearing 1)
^ For drive pinion
18 - Circlip
^ Removing
19 - Shim "S3"
^ Note thickness
^ Adjustment overview
20 - Needle bearing
^ For input shaft
^ Measuring insertion depth
21 - Locking bolt
^ For selector shaft
^ Tightening torques: For aluminium bolt = 50 Nm, and for steel bolt = 70 Nm
22 - Breather
^ Clip cap on
^ For transmission with sleeve insertion depth of sleeve
^ For transmission with additional breather hose
23 - Trunnion bolt, 40 Nm
^ For push rod
24 - Seal for selector shaft
^ Can be replaced when transmission is removed but not disassembled
^ Always replace
^ Always use assembly sleeve for installing
25 - Transmission housing 1)
26 - Magnet
^ Clean
^ When replacing transmission housing drive in with e.g. press tool VW 408 A
27 - Sender for speedometer -G22
^ Replace
28 - O-ring
^ Always replace
29 - Oil filler plug, 40 Nm
Pull out seal for drive flange
Note:
^ Illustrated, removing oil seal on right-hand side.
^ Procedure for removing oil seal on left and right-hand sides is identical.
Drive in seal for drive flange
- Fill space between sealing lip and dust lip with sealing grease G52 128 A1.
^ Pressing-in depth (factory): 5.5 mm
^ Pressing-in depth when re-installing a used drive flange (repairs): 6.5 mm
Note:
^ Illustrated, installing oil seal on right-hand side.
^ Procedure for installing oil seal on left and right-hand sides is identical.
Prying out seal for input shaft when transmission is dismantled
- Pry out seal carefully with VW 681.
Remove seal for input shaft when transmission is not dismantled
- Pry out seal carefully with a screwdriver.
Note:
Do not damage bearing surface on input shaft for shaft seal.
Drive in seal for input shaft
- Fill space between sealing lip and dust lip of new seal for input shaft with sealing grease G52 128 A1.
- Fit a thin protective hose tightly over splines of input shaft.
- Drive in seal for input shaft.
^ Pressing-in depth (factory): 3.5 mm
^ Pressing-in depth when re-installing a used input shaft (repairs): 4.5 mm
- Remove protective hose.
Pull out ball sleeve
- Remove circlip.
A - Internal puller 14.5-18.5 mm, e.g. Kukko 21/2
Drive in ball sleeve
- Drive in onto stop.
Pull out seal for selector shaft
Note:
With transmission removed but not disassembled, carefully pry out seal without damaging the shaft with a screwdriver.
Drive in seal for selector shaft
^ Selector shaft installed or removed
- Fill space between sealing lip and dust lip with sealing grease G52 128 A1.
- Pull assembly sleeve onto selector shaft.
- Drive seal into housing onto stop.
Install seal and selector shaft with assembly sleeve
- To avoid damaging seal -C- always use assembly sleeve -A-, Part No. 01E 311 120, to install seal or selector shaft.
Insertion depth of breather sleeve for transmissions without breather hose
^ Dimension a = 21 mm
Breather for transmission with breather hose
1 - Transmission
2 - Sleeve: drive in onto stop
3 - Pipe: drive in onto stop
4 - Clamp
5 - Hose
6 - Breather pipe
7 - Retaining clip
Pull needle bearing out of transmission housing
A - Internal puller 30-37 mm, e.g. Kukko 21/5
Drive needle bearing into transmission housing
^ Installation position: inscription on bearing faces tool
^ Insertion depth
Insertion depth of needle bearing
Dimension a = 105 mm
Remove circlip
- Lift circlip out of groove by turning one end of circlip with a screwdriver -A-.
- Secure this end with a screwdriver -B-.
- Pry circlip out further by repositioning screwdriver -A-.
Installation position of oil baffle plate for transmission DSY
1 - Breather
2 - Oil baffle plate
3 - Selector shaft