Transmission Housing, Repairing

Transmission housing, repairing





Special tools and equipment
^ VW 309 holding plate
^ VW 353 transmission support
^ VW 407 punch
^ VW 771 slide hammer complete set
^ 12 551 centering drift
^ 3129 seal driver





Special tools and equipment
^ 3176 centering drift





1. Kukko 21/2 extractor
1. Kukko 21/4 extractor





1. Transmission housing
^ Clamp into mounting block
^ In case of replacement: adjust input shaft, pinion shafts and differential.
2. Sealing washer
^ Always replace
3. Oil drain plug, 30 Nm
4. Locking sleeves
^ Driving out, Refer to Fig. 2
^ Driving in, Refer to Fig. 3
5. Oil filler plug, 30 Nm
6. Detent pin
^ Is pressed into the selector shaft to adjust the outer shift mechanism
^ Driving out, Refer to Fig. 4
^ Driving in, Refer to Fig. 5
7. Bearing sleeve
^ For shift rods
^ Replace after every disassembly
^ Pulling out, Refer to Fig. 6
^ * Installing, Refer to Fig. 7
8. Needle sleeve
^ Replace after every disassembly
^ Pulling out, Refer to Fig. 8
^ Pressing in, Refer to Fig. 9
9. Adjustment shim
^ For input shaft
^ Adjustment overview, Refer to Differential, Adjustments
10. Tapered roller bearing outer race
^ For input shaft
^ Removing and installing, Refer to, Overhaul Subassemblies Input Shaft, Disassembling and Assembling.
^ In case of replacement:, Refer to, Overhaul Subassemblies, Input shaft, adjusting
11. Tapered roller bearing outer race
^ For pinion shaft 5th/6th and reverse gear
^ Removing and installing, Refer to, Overhaul Subassemblies, 5TH/6TH and Reverse Gear Pinion Shaft, Disassembling and Assembling
^ In case of replacement: pinion shaft 5th/6th and reverse gear, adjusting, Refer to Overhaul Assemblies, Pinion Gear For 5TH/6TH and Reverse Gear, Adjusting.
12. Adjustment shim
^ For pinion shaft 5th/6th and reverse gear
^ Adjustment overview , Refer to Differential, Adjustments
13. Tapered roller bearing outer race
^ For pinion shaft 1st to 4th gear
^ Removing and installing, Refer to, Overhaul Subassemblies, Pinion Shaft 1ST to 4TH Gear, Disassembling and Assembling
^ In case of replacement: pinion shaft 1st to 4th gear, adjusting, Refer to, Overhaul Subassemblies, 1ST-4TH Gear Pinion Shaft, Adjusting
14. Adjustment shim
^ For pinion shaft 1st to 4th gear
^ Adjustment overview, Refer to Differential Assembly, Adjustments
15. Tapered roller bearing outer race
^ For differential
^ Removing and installing, Refer to Differential Assembly, Service and Repair
^ In case of replacement: adjusting differential, Refer to Differential, adjustments
16. Adjustment shim
^ For differential
^ Adjustment overview, Refer to Differential, adjustments
17. Sealing washer
^ Replacing, Refer to Seals and Gaskets, Differential





Fig. 1 Securing transmission housing to mounting block with bolts (arrows)





Fig. 2 Driving out locking sleeve





Fig. 3 Drive in locking sleeve to stop
- Using 13 mm socket - A - and plastic hammer, drive in locking sleeve to stop.





Fig. 4 Driving out detent pin





Fig. 5 Drive in detent pin - A - to stop





Fig. 6 Pulling out bearing sleeve for shift rod
A - extractor 14.5 ... 18.5 mm, z. B. Kukko 21/2





Fig. 7 Drive in bearing sleeve for shift rod until flush





Fig. 8 Pulling out needle sleeve for reverse shaft from transmission housing
A - extractor 23.5 30 mm, z. B. Kukko 21/4

Notes: Needle sleeve is destroyed during removal and must be replaced.





Fig. 9 Pressing in needle sleeve - A - into transmission housing
- Place thrust washer - B - from reverse shaft onto needle sleeve during installation process.