Transmission Housing, Servicing
Transmission housing, servicing, 01E, 6 Spd. M/T AWD
Special tools and equipment:
^ VW 408 A Press tool
^ VW 423 Tube
^ VW 454 Thrust pad
^ VW 681 Seal extractor
^ VW 771 Multi-purpose tool
^ 10-15 Guide pins
Special tools and equipment (continued):
^ 30-100 Thrust sleeve
^ 30-505 Fitting mandrel
^ 40-503 Inserting drift
^ 2062 Fitting drift
^ 1 - Kukko 21/2 Internal puller and Kukko 21/5 Internal puller
^ V.A.G 1331 Torque wrench (5 to 50 Nm)
^ Depth gauge
^ Assembly sleeve Part No. 01E 311 120
1) Adjustments are required if these components are replaced go to Adjustment overview.
1 - Seal for flanged shaft
^ Pulling out go to Fig. 1
^ Tapping in go to Fig. 2
^ Pack space between sealing lips with sealing grease
^ Replacing with transmission installed
2 - Cover 1)
^ For final drive
3 - O-ring
^ For cover for final drive
^ Always replace
4 - Shim S1
^ Note thickness
^ Adjustment overview
5 - Taper roller bearing outer race, large1)
^ For differential
^ Removing and installing, go to Fig. 11 and go to Fig. 12
6 - Taper roller bearing outer race, small 1)
^ For differential
^ Removing and installing, go to Fig. 9 and go to Fig. 10
7 - Shim S2
^ Note thickness
^ Adjustment overview
8 - Seal
^ For input shaft
^ Levering out go to Fig. 3
^ Tapping in go to Fig. 5
^ Always replace when removing input shaft
^ Replacing when transmission is not disassembled go to Fig. 4 and go to Fig. 5
9 - Oil drain plug, 40 Nm
10 - Ball sleeve for selector shaft
^ Pulling out go to Fig. 6
^ Tapping in go to Fig. 7
11 - Ball sleeves for selector rods
^ Pulling out as -item 10- go to Fig. 6
^ Driving in as -item 10- go to Fig. 7
12 - Circlip
^ Installation position: Eyes facing up
13 - Switch for reversing light, 20 Nm
^ Removing and installing go to Fig. 12
14 - O-ring
^ For selector shaft cover
^ Always replace
^ Coat with gear oil when installing
15 - Cover for selector shaft
^ Removing
^ Installing
16 - Ball stud, 20 Nm
^ For connecting rod
17 - Taper roller bearing outer race, large1)
^ For drive pinion
^ Pulling out, go to Fig. 1
^ Pressing in, go to Fig. 2
18 - Circlip
^ Removing go to Fig. 16
19 - Shim S3
^ Note thickness
^ Adjustment overview
20 - Needle bearing for input shaft
^ Pulling out go to Fig. 13
^ Tapping in go to Fig. 14
^ Measuring insertion depth go to Fig. 15
21 - Locking bolt for selector shaft, 50 Nm
^ Removing
^ Insert in transmission housing with sealing paste AMV 188 001 02
22 - Trunnion bolt, 40 Nm
^ For push rod
23 - Breather
^ Insertion depth of sleeve go to Fig. 11
^ Clip cap on
24 - Selector shaft seal
^ Can be replaced when transmission is removed but not disassembled
^ Always replace
^ Pulling out go to Fig. 8
^ Tapping in go to Fig. 9
^ Always use assembly sleeve for installing go to Fig. 10
25 - Transmission housing 1)
26 - Solenoid
^ Clean
^ Drive in (for example, with press tool VW 408 A) when replacing transmission
27 - Speedometer vehicle speed sensor -G22-
^ Replacing
28 - O-ring
^ Always replace
29 - Oil filler plug, 40 Nm
Fig. 1 Pulling out seal for flanged shaft
Notes:
^ Figure shows removing seal on right-hand side of transmission.
^ The procedure is identical for left and right-hand seals.
Fig. 2 Driving in seal for flanged shaft
^ Insertion depth: 5.5 mm
Notes:
^ Figure shows installing seal on right-hand side of transmission.
^ The procedure is identical for left and right-hand seals.
^ Insertion depth for repairs is 6.5 mm when a used flanged shaft is employed.
Fig. 3 Levering out input shaft seal when transmission is disassembled
Fig. 4 Removing input shaft seal when transmission is not disassembled
- Lever out seal carefully with a screwdriver.
Note: Do not damage bearing surface on input shaft for shaft seal.
Fig. 5 Drive in input shaft seal flush
- Pack new seal for input shaft between sealing lip and dust lip half full with sealing grease.
- Pull a thin protective hose tightly onto splines of input shaft.
- Tapping in input shaft seal.
^ Insertion depth: 3.5 mm
Note: Insertion depth for repairs is 4.5 mm when a used input shaft is employed.
- Remove protective hose.
Fig. 6 Pulling out ball sleeve
- Remove circlip.
A - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2
Fig. 7 Driving in ball sleeve
- Install ball sleeve with the inscribed side (thicker metal) facing the drift.
- Drive in onto stop.
- Install circlip.
Fig. 8 Pulling out selector shaft seal
Note: With transmission removed but not disassembled, carefully lever out seal without damaging the shaft with a screwdriver.
Fig. 9 Driving in selector shaft seal
^ Selector shaft installed or removed
- Pack space between sealing and dust lips half full with sealing grease.
- Pull assembly sleeve onto selector shaft go 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. 01E 311 120, to install seal or selector shaft.
Fig. 11 Insertion depth of breather sleeve
^ Distance a = 21 mm
Fig. 12 Removing and installing reversing light switch
- Tighten reversing light switch -A- to 20 Nm when installing.
Fig. 13 Pulling needle bearing out of transmission housing
A - Internal extractor 30 to 37 mm, e.g. Kukko 21/5
Fig. 14 Driving needle bearing into transmission housing
^ Installation position: Inscription on bearing faces drift
^ Insertion depth go to Fig. 15
Fig. 15 Insertion depth of needle bearing
^ Distance a = 105 mm
Fig. 16 Removing circlip
- Lift circlip out of the groove by turning one end of circlip with a screwdriver -A-.
- Secure this end with a screwdriver -B-.
- Lever circlip out further by repositioning screwdriver -A-.