Transmission Housing

Transmission Housing

Special tools, testers and auxiliary items required

• Guide Pin (VW 436 A)

• Guide Pin (VW 439)

• Slide Hammer-Complete Set (VW 771)

• Holding Fixture (VW 801)

• Guide Pin (10 - 15)

• Thrust Pad (3124)

• Driving Sleeve (VW 244 B)

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Sleeve (VW 416 B)

• Driver (3264)

• Subframe Support Assm. Device (3290)

• Drift (T10168)

• Drift (T10169)

• Thrust piece (T10203)

• Kukko 21/2 Internal puller and Kukko 21/4

• Kukko 22/2 counter-support

• Drift (T10362)

Removing Cap - A -

- Knock rubber through at center of sealing cap using a screwdriver - B - and pry out cap in direction of - arrow -.





Driving In Sealing Cap

- Drive in sealing cap up to the stop.





Removing Lock Elbow for Selector Shaft

- Break off the pin in released position.

- Guide a screwdriver - A - into hole - B - of the lock elbow.





- Pry out lock elbow - arrow -.

Installation Position of Lock Elbow

• The marking on the lock elbow - arrow - must point to clutch slave cylinder connection - 1 -.





• The angle - a - must be approximately 45°.

Drive in the Lock Elbow for the Selector Shaft.

• The lock elbow - arrow - must be released for the driving-in procedure.





- Drive in the lock elbow to the tool stop.

Pulling Out Bearing Bushing for Selector Rod





A Internal puller 14.5 to 18.5 mm, for example (Kukko 21/2)
B Support, for example (Kukko 22/2)

Driving In Bushing for Selector Rod

- Drive in bushing for selector rod up to the stop when tool makes contact.





Pressing Out Lock Sleeve with Transmission Disassembled

- Arrange transmission housing on (VW 401) and (VW 402) so that alignment bushings in transmission housing are not damaged.





- Press out the lock sleeve - A -.

Driving Out Lock Sleeve with Transmission Assembled

• Locking bolt and selector shaft removed.

- Rotate transmission so that lock sleeve does not fall into transmission.

- Drive out the lock sleeve using (10 - 15).





Lock Sleeve Differentiation

- A lock sleeve with shoulder - arrow 1 - and without shoulder - arrow 2 - can be installed.





- Allocate components, refer to the electronic parts catalog ETKA.

Drive In Lock Sleeve with Shoulder as Far as Stop on Tool





• Transmission housing fastened to clutch housing.

Drive In Lock Sleeve without Shoulder as Far as Stop on Tool





• Transmission housing fastened to clutch housing.

Pulling Needle Bearing for Reverse Shaft Out of Transmission Housing





A Internal puller 23.5 to 30 mm, for example (Kukko 21/4)
B Support, for example (Kukko 22/2)

• Needle bearing is destroyed when it is removed and must be replaced.

Press Needle Bearing into Transmission Housing





- During pressing sequence, place thrust washer - B - for reverse shaft onto the needle bearing - A -.

- Support the transmission housing with the (VW 416 B) directly under the bearing mount.

Pulling Out Bushing for Selector Shaft





- Hold spindle of assembly tool (3290) firmly in place and screw nut - B -.

A Internal puller 14.5 to 18.5 mm, for example (Kukko 21/2)

Driving In Bushing for Selector Shaft

- Drive selector shaft bushing - A - in flush.





Driving Out Sealing Plug

- Drive the sealing plug - 1 - from the inner side of the transmission housing toward the outside - arrow -.





Driving In Sealing Plug

- Drive in the sealing plug - 1 - using the (3264) to dimension - a - = approximately 3 mm under the upper edge of housing.