Transmission Without Circlip A For Cap/Input Shaft
Transmission without Circlip A for Cap/Input Shaft
Transmission without Circlip - A -.
Remove and install the transmission housing, shift mechanism, input shaft, output shafts, differential bevel box, and selector rods
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Tube (VW 455)
• Slide Hammer-Complete Set (VW 771)
• Kukko 21/1 internal puller
• Kukko 17/0 separating tool
• Kukko 22/1 counter-support
• Bracket (30 - 211 A)
• Thrust Piece (T10042)
• Drift (T10169)
• Thrust Piece (T40008)
• Torque Wrench (V.A.G 1331)
• Heat Gun (V.A.G 1416)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Extractor Lever (VW 681)
• Socket and Extended Bit (T10107 A)
Disassembling
• Transmission removed, refer to => [ Transmission, Removing ] Transmission, Removing and secured to the assembly stand => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.
- Rotate transmission in assembly stand with oil drain plug downward.
- Place the (V.A.G 1782) under the transmission.
- Drain gear oil from manual transmission.
- Remove the right flange shaft bolt using the (T10107 A).
- Remove 4 bevel box connecting bolts - arrows - (only 3 shown in illustration) at manual transmission.
- Carefully press bevel box off manual transmission while protecting it against falling through.
- Remove bolts - arrows -.
- Remove the clutch slave cylinder together with release bearing - A -.
- In the following step, ensure that the selector shaft is not locked by the lock elbow - arrow -.
- Move shift shaft to neutral position.
- Remove mounting bolt - 2 -.
- Remove the bolts - 3 -.
- Remove back-up light switch (F4) - 1 -.
- Pull selector shaft - 4 - off transmission housing.
- Remove the left flange shaft bolt by installing 2 bolts in the flange and counter holding the flange shaft with the assembly lever.
- Remove bolts - B - inside clutch housing for securing clutch housing to transmission housing.
• One bolt - arrow - is located outside of bolting flange.
- Secure the input shaft by inserting the (VW 455) over the input shaft, onto the clutch housing.
- Then tension separating tool - A -, for example (Kukko 17/0) tightly behind input shaft splines.
• Back side of separating tool must contact pressing sleeve free of play.
- Knock rubber through in center of cap - C - using a screwdriver.
- Remove cap from transmission housing.
A Support, for example (Kukko 22/1)
B Internal puller 8 to 12 mm, for example (Kukko 21/01)
Remove circlip - C - from input shaft grooved ball bearing in the following manner:
- Hold one end of circlip in place using screwdriver - A -.
- With the 2nd screwdriver - B -, pry the other end of the circlip out of the groove of the grooved ball bearing - arrow -.
- By repositioning the screwdriver - B -, pry the circlip further out.
- If present, remove spacer washer - 1 - from transmission housing - 2 -.
• If the transmission housing is replaced, check whether the spacer washer needs to be reinstalled.
- Remove bolts - A -.
- Screw adapter (VW 771/40) into threaded hole of transmission housing.
- Heat the transmission housing using the hot air blower (V.A.G 1416) in the area of the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.
- Pull off transmission housing from clutch housing - arrow - using (VW 771/1).
• If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.
- If present, remove spacer washer - 1 - from grooved ball bearing - 2 -.
- If the transmission housing is replaced, check whether the spacer washer needs to be reinstalled.
- Remove separating tool - A - and (VW 455) from input shaft.
A 2nd technician is required to remove shafts from clutch housing.
- Lift differential - 1 - with the left hand.
- With the right hand, lift output shaft for 1st to 4th gears together with selector rods - 2 - - arrow A -.
- At the same time, 2nd technician lifts input-, reverse- and output shaft for 5th/6th gear - 3 - together with selector rods out of clutch housing - arrow B -.
• If necessary, differential can be shifted again in clutch housing after lifting shafts.
- Drive out sealing ring for input shaft using sleeve (30-21).
• Grooved ball bearing on input shaft must always be replaced => [ (Item 6) ] Input Shaft Assembly Overview.
Assembling
• A new grooved ball bearing must be pressed on to input shaft => [ (Item 6) ] Input Shaft Assembly Overview.
• Tightening specifications => [ Transmission Housing and Shift Mechanism Assembly Overview ] Transmission Housing and Shift Mechanism Assembly Overview.
- First insert input shaft - 1 -, output shaft for 5th/6th gears - 2 - together with selector rod - 3 -, shift fork - 4 - and reverse shaft - 5 -.
- Insert differential - 1 -.
• A 2nd technician is required for further installation of shafts into clutch housing.
- As shown in illustration, take output shaft for 1st to 4th gears - 3 - with selector rods - 4 - in right hand.
- Lift the differential slightly with the left hand.
- At the same time, 2nd technician slightly lifts input shaft, output shaft for 5th/6th gears and reverse gear - 2 - together with reverse shaft.
- Now, insert the output shaft for 1st to 4th gears in direction of - arrow -.
• Places of input shaft, output shafts and final drive gear/differential must engage.
- Together with a 2nd technician, place the shafts and the differential into their bearing seats.
- Fasten the bracket (30 - 211 A) for the input shaft to the clutch housing.
• For the sake of illustration, clutch housing is depicted rotated 180°.
- Screw in bolt - A - far enough until input shaft rises slightly.
• With some transmissions, there are flattened areas - A - on the input shaft grooved ball bearing and on the bearing mount - B -.
• Check the input shaft grooved ball bearing and the transmission housing.
From transmission build date 4.10.06 through approximately 1.21.08
One spacer washer is inserted above and below the input shaft grooved ball bearing - 6 - => [ Grooved Ball Bearing ] Input Shaft Assembly Overview.
Measure the Shoulder above the Grooved Ball Bearing Mount.
The Area Below the Grooved Ball Bearing Seat in the Transmission Housing has been Changed - arrow -
- Place a spacer washer (85 mm outer circumference) - 1 - on grooved ball bearing - 2 -.
In the Case of Transmissions with Flattened Areas - A - on the Grooved Ball Bearing for the Input Shaft and on Bearing Mount - B -
• Do not place any spacer washers above and below the grooved ball bearing.
• Flattened areas - A - on the grooved ball bearing and on bearing mount - B - must align in the transmission housing.
- Mark the flattened areas with color.
- Place a marking on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (=> next illustration).
- Heat the transmission housing using the hot air blower (V.A.G 1416) in the area of the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.
• It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.
- Align the marking on the grooved ball bearing - A - with the marking on the transmission housing - B - and mount the transmission housing.
Continuation for all transmissions
- Heat the transmission housing using the hot air blower (V.A.G 1416) in the area of the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.
• It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.
- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.
- Install transmission housing and tighten new bolts - A -, - B - and - C - to tightening specification.
Allocation of bolts:
A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer
- If a spacer washer was mounted on the grooved ball bearing before installation of the transmission housing, a spacer washer - 1 - (outer diameter = 78.6 mm) must also be installed after installation of transmission housing - 2 -.
- Install circlip - 1 - for grooved ball bearing/input shaft.
- Remove (30 - 211 A) for input shaft.
- If lock sleeve for selector shaft has been removed, drive it in now using (T10169) until tool makes contact.
- Turn transmission with opening for selector shaft in assembly stand upward.
- Insert selector shaft - 1 - into lower mounting - 2 - and into shift forks - 3 -.
• To improve clarity, the cap is removed.
- Now press selector shaft - 1 - against lock sleeve - 2 - in direction of - arrow - and guide downward with shift finger - 3 - through shift forks until stop.
• Shift cover - 4 - must stand parallel to bolting surface on transmission housing during this.
• Selector shaft must be able to be moved easily in selector motion (up- and downward).
• If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.
- Tighten the bolts - 3 - for the shift cover - 4 -.
- Install lock bolt - 2 -, lock bolt - arrow - must not be installed when doing so.
- Install back-up light switch (F4) - 1 -.
- Install left flange shaft. Refer to => [ Flange Shaft and Seals on Transmission Assembly Overview ] Flange Shaft and Seals on Transmission Assembly Overview.
- Drive in the input shaft sealing ring.
- Install the clutch slave cylinder with release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Service and Repair.
- Shift through all gears.
- Drive cap into transmission housing to stop of (T10042)
Install bevel box in manual transmission as follows:
Risk of damaging sealing ring between transmission and bevel box.
• Place bevel box on transmission together with right flange shaft while turning shaft.
- With manual transmission, lubricate differential splines with grease for clutch disc shaft splines (G 000 100).
- Slide on bevel box completely on manual transmission, while doing this, join splines of input shaft/bevel box centrally with differential.
- With proper tooth position and central guiding, bevel box slips up to stop against manual transmission.
• Do not pull bevel box with mounting bolts against manual transmission, otherwise bevel box is canted and mounting eyelets can break off.
- Tighten 4 bevel box connecting bolts - arrows - (only 3 shown in illustration) at manual transmission. Tightening specifications - 10 - => [ Bolt ] Flange Shaft and Seals on Bevel Box Assembly Overview.
- Install right flange shaft. Refer to => [ Flange Shaft and Seals on Bevel Box Assembly Overview ] Flange Shaft and Seals on Bevel Box Assembly Overview.