Transmission Housing, Servicing

Transmission housing, servicing
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 sleeve30-100
^ 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. 01 E 311 120

Note:
^ General repair instructions, Refer to Manual Transaxle, Service and Repair
^ Adjustments are required when replacing components marked 1), Refer to Differential Assembly, Adjustments, adjustment overview.





1. Seal
^ For drive flange
^ Pulling out, Refer to Fig. 1
^ Driving in, Refer to Fig. 2
^ Fill space between sealing lips with sealing grease G52 128 A1
^ Replacing with transmission installed, Refer to Seals and Gaskets, Differential
2. Final drive cover 1)
3. O-ring
^ For cover for final drive
^ Always replace
4. Shim "S1"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, Adjustments,adjustment overview
. 5. Outer race for large tapered roller bearing 1)
^ For differential
^ Driving out and driving in, Refer to Differential, Assembly, Service and Repair
6. Outer race for small tapered roller bearing 1)
^ For differential
^ Driving out and driving in, Refer to Differential, Assembly, Service and Repair
7. Shim "S2"
^ Note thickness
^ Adjustment overview, Refer to Differential, Assembly, Adjustments
8. Seal
^ For input shaft
^ Prying out, Refer to Fig. 3
^ Driving in, Refer to Fig. 5
^ Always replace when removing input shaft
^ Replacing when transmission is not disassembled, Refer to Fig. 4 and Fig. 5
9. Oil drain plug, 40 Nm
10. Ball sleeve
^ For selector shaft
^ Replace
^ Pulling out, Refer to Fig. 10.
^ Driving in, Refer to Fig. 7
11. Ball sleeves
^ For selector shafts
^ Replace
^ Pulling out, as 10, Refer to Fig. 6
^ Driving in, as 10, Refer to Fig. 7
12. Circlip
^ Installation position: eyes facing up
13. Switch for backup lights, 20 Nm
14. O-ring
^ For cover for selector shaft
^ Always replace
15. Cover for selector shaft
^ Removing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly sequence)
^ Installing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly sequence)
16. Ball stud, 20 Nm
^ For connecting rod
17. Outer race for large tapered roller bearing 1)
^ For drive pinion
^ Pulling out, Refer to Overhaul Subassemblies, Drive Pinion and Hollow Shaft, Disassembling and Assembling, See Fig. 1
^ Pressing in, Refer to Overhaul Subassemblies, Drive Pinion and Hollow Shaft, Disassembling and Assembling, See Fig. 2 and Fig. 3
18. Circlip
^ Removing, Refer to Fig. 16
19. Shim "S3"
^ Note thickness
^ Adjustment overview, Refer to Differential Assembly, Adjustments
20. Needle bearing
^ For input shaft
^ Pulling out, Refer to Fig. 13
^ Driving in, Refer to Fig. 14
^ Measuring insertion depth, Refer to Fig. 15
21. Locking bolt
^ For selector shaft
^ Removing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly sequence)
^ Installing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly sequence)
^ Tightening torques: For aluminum bolt = 50 Nm, and for steel bolt = 70 Nm
22. Breather
^ Clip cap on
^ For transmission with sleeve insertion depth of sleeve, Refer to Fig. 11
^ For transmission with additional breather hose, Refer to Fig 12
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
^ Pulling out, Refer to Fig. 8
^ Driving in, Refer to Fig. 9
^ Always use assembly sleeve for installing, Refer to Fig. 10
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-
^ Replacing, Refer to Powertrain Management
28. O-ring
^ Always replace
29. Oil filler plug, 40 Nm





Fig. 1 Pulling 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.





Fig. 2 Driving 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.





Fig. 3 Prying out seal for input shaft when transmission is dismantled
- Pry out seal carefully with VW 681.





Fig. 4 Removing seal for input shaft when transmission is not dismantled
- Pry out seal carefully with a screwdriver.

Note: Do not damage bearing surface input shaft for shaft seal.





Fig. 5 Driving 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.





Fig. 6 Pulling out ball sleeve
- Remove circlip.
A- Internal puller 14.5-18.5 mm, e.g. Kukko 21/2





Fig. 7 Driving in ball sleeve
- Drive in onto stop.





Fig. 8 Pulling out seal for selector shaft

Note: With transmission removed but not disassembled, carefully pry out seal without damaging the shaft with a screwdriver.





Fig. 9 Driving 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, Refer to Fig. 10.
- Drive seal into housing onto stop.





Fig. 10 Installing seal and selector shaft with assembly sleeve
- To avoid damaging seal -C- always use assembly sleeve -A-, Part No. 01 E 311 120, to install seal or selector shaft.





Fig. 11 Insertion depth of breather sleeve for transmissions without breather hose
^ Dimension a , = 21 mm





Fig. 12 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





Fig. 13 Pulling needle bearing out of transmission housing
A - Internal puller 30-37 mm, e.g. Kukko 21/5





Fig. 14 Driving needle bearing into transmission housing
^ Installation position: inscription on bearing faces tool
^ Insertion depth = Fig. 15





Fig. 15 Insertion depth of needle bearing
Dimension a = 105 mm





Fig. 16 Removing 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-.





Fig. 17 Installation position of oil baffle plate for transmission -A-.
1. Breather
2. Oil baffle plate
3. Selector shaft