Transmission Cover
Transmission Cover
Special tools, testers and auxiliary items required
• Arbor (VW 204 B)
• Drift (VW 207 C)
• Punch (VW 408 A)
• Punch (VW 411)
• Punch (VW 412)
• Sleeve (VW 420)
• Sleeve (VW 423)
• Arbor (VW 434)
• Sleeve (VW 472/2)
• Thrust Pad (VW 512)
• Guide Pin (10 - 15)
• Sleeve (40 - 21)
• Thrust Pad (3005)
• Drift (3138)
• Extension (3161)
• Support Arm Bearing Inst. Tool (3346)
• Guide Bearing Inst. Tool (3347)
• Shock Absorber Set (T10001)
• Pulling Hook (T20143)
• Drift (T40085)
• Pressure Sleeve (T40103)
• Sealing Paste (AMV 188 001 02)
• Sealing Grease (G 052 128 A1)
1 Large Securing Bushing
• For selector shaft
• Removing and installing
• Installation dimension
2 Securing Bushing
• For the gearshift rail / shift fork
• Removing and installing, refer to is currently not possible.
3 Needle Bearing
• Always replace
• For the side shaft bearing
• Remove from the transmission cover using the (3138)
• Driving in
• Secure after installing with peen
4 Oil Collector Tray
• Install in the openings in the transmission cover and roller sleeves - 6 -
5 Outer Race / Tapered Roller Bearing
• For the gear wheel mounting inside the transmission cover
• Removing
• Installing
6 Roller Sleeve
• For the input shaft mounting
• Removing
• Installing
7 Transmission Cover
8 O-Ring
• Always replace
• Installed only on transmissions with a cover / gearshift shaft together with a transmission neutral position sensor (G701) or cap
9 Sealing Cap
• For the gearshift shaft together with a transmission neutral position sensor or a cap
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Assembly overview
• Selector shaft seal, removing and installing
• Remove the gearshift shaft ball sleeve
• Install the gearshift shaft ball sleeve
10 Sealing Cap
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Replace the O-ring with a cap, use the transmission code to allocate, refer to the electronic parts catalog ETKA
11 Bolt
• Always replace
• 10 Nm plus an additional 45° turn
• Aluminum bolts (M8; 22 mm long)
12 Transmission Neutral Position Sensor (G701)
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Replace the O-ring on the transmission neutral position sensor, allocate according to the transmission code, refer to the electronic parts catalog ETKA
13 Sealing Cap
• For the gearshift shaft without a transmission neutral position sensor or a cap
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Assembly overview
• Selector shaft seal, removing and installing
• Remove the gearshift shaft ball sleeve
• Install the gearshift shaft ball sleeve
14 Bushing
• For the 3rd/4th gear gearshift rail / shift fork
• Removing
• Installing
15 Small Locking Bushing
• For selector shaft
• Removing and installing is currently not possible.
Removing and Installing the Large Locking Bushing - 1 - on the Gearshift Shaft
• The gearshift shaft must be removed.
• If the transmission is not disassembled, place a cloth in the opening for the gearshift shaft to prevent the locking bushing from falling into the transmission.
- Remove the large locking bushing using the (T40085) toward the inside, in the transmission cover.
- Install the locking bushing using the (T40085) to the installation dimension.
Installed Dimension for the Large Locking Bushing - 1 - Inside the Transmission Cover
- Check the installed dimension - a - = 5 ± 0.2 mm with a depth gauge - 2 -.
• Insert the depth gauge on the first shoulder - arrow - of the locking bushing.
Installing the Needle Bearing all the way into the Transmission Cover
• Remove peening indentations, if present.
Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards (VW 204 B).
- Secure needle bearing after pressing into transmission cover with peen.
Securing the Needle Bearing Inside the Transmission Cover by Peening it
- To peen, use blunt center punch with ball-shaped end (ball diameter 5 mm).
- Needle bearing is secured with 4 peening marks on circumference every 90° - arrows -.
Observe position and diameter of peening points:
• Dimension - a - = 2 mm
• Dimension - b - = 3 mm
Pressing Tapered Roller Bearing Outer Race out from the Transmission Cover
Installing the Outer Race / Tapered Roller Bearing all way into the Transmission Cover
Removing the Input Shaft Roller Sleeve from the Transmission Cover
Installing the Input Shaft Roller Sleeve - A - all the way into the Transmission Cover
• Mount the roller sleeve with the shoulder into the open side of the (3346).
Removing and Installing the Gearshift Shaft Cover - A -
• The gearshift shaft is removed.
- Remove the bolts that attach the cover - A - to the transmission cover.
- Remove the cover using the (VW 420) in direction of - arrow -.
- Clean the sealing surfaces on the cover and transmission cover.
- Apply sealing compound (AMV 188 001 02) evenly and use new bolts to attach the cover - 11 -.
Gearshift Shaft Cover Assembly Overview
1. Selector shaft seal, removing and installing
2. Sealing cap
3. Gearshift shaft ball sleeve, removing and installing
Assembly Overview - Gearshift Shaft Cover with a Hole - arrow - for the Transmission Neutral Position Sensor (G701) or Cap
1. Selector shaft seal, removing and installing
2. Sealing cap
3. Gearshift shaft ball sleeve, removing and installing
4. O-Ring
Gearshift Shaft Seal, Removing and Installing
- Pry out the shaft seal using the (T20143/1).
- Lightly oil outer circumference of shaft seal.
- Fill area between sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Install the shaft seal using the (T10001/1) or the tube (VW 423).
• Installed dimension: 2 mm under the upper edge of the cover
Removing the Gearshift Shaft Ball Sleeve from the Cover
Installing the Gearshift Shaft Ball Sleeve - A - Evenly in the Cover - B -
Set ball sleeve in place with inscribed side (thicker wall) facing toward (10 - 15).
Installing the Gearshift Shaft Ball Sleeve - A - up to Dimension - x - into the Cover - B -,
Set ball sleeve in place with inscribed side (thicker wall) facing toward (10 - 15).
• Installed dimension - x - = 2.5 ± 0.5 mm
Removing the Bearing Bushing for the 3rd and 4th Gear Gearshift Rail /. from the Transmission Cover
Installing the Bearing Bushing - A - for the 3rd and 4th Gear Gearshift Rail / Shift Fork all the way into the Transmission Cover
- Install the (3161) and shoulder - arrow 1 - in the bearing bushing - A -.
- Install the bearing bushing all the way using the (VW 207 C) and at the same time with the shoulder - arrow 2 - into the (3161).