Transmission With Circlip A For the Cap/Input Shaft
Transmission with Circlip A for the Cap/Input Shaft
Transmission with 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 (30-211A)
• Thrust piece (T10042)
• Thrust piece (T10143)
• Thrust piece (T40008)
• Torque Wrench (V.A.G 1331)
• Heat gun (V.A.G 1416)
• Drift (T10169)
• or Drift (T10362) => [ Lock Sleeve Differentiation ] Transmission Housing
• Extractor Lever (VW 681)
• Oil Collecting and Extracting Device (V.A.G 1782)
• Socket and Key (T10107 A)
Removing
• 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 drip tray underneath.
- Drain gear oil from manual transmission.
- Remove the right flange shaft bolt with 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 the clutch slave cylinder with the release bearing - arrows -.
- 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.
- Remove the cap/input shaft circlip - A -.
- 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 screwdriver - B -, pry the circlip out further.
- Remove mounting bolts - A - for transmission housing at clutch housing.
- Screw adapter (VW 771/40) into threaded hole of transmission housing.
- Heat the transmission housing using the (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 slide hammer (VW 771/1).
• If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.
- 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.
- Pry off the shaft sealing ring for the input shaft with the (VW 681).
• Grooved ball bearing on input shaft must always be replaced - 6 -=> [ Grooved Ball Bearing ] Input Shaft Assembly Overview.
Transmission, Assembling
• A new grooved ball bearing must be pressed on to input shaft - 6 - => [ Grooved Ball Bearing ] Input Shaft 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 -.
To transmission build date 5/24/09
• Bearing for reverse gear shift fork:
- Mount reverse gear shift fork - 1 - on axle - 2 - behind 5th/6th gear selector rod - 3 -.
From Transmission Build Date 5/25/09
• Bearing for reverse gear shift fork:
- Mount reverse gear shift fork - 1 - on the selector rod with 5th/6th gear shift fork - 2 -.
Continuation for all Transmissions
- 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 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 (30-211A) 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.
• The grooved ball bearing/input shaft only fits in one position in the transmission housing.
There is a flattened area on the grooved ball bearing and the bearing mount.
• If flattened areas - A - and - B - are present, do not insert any spacer washers above and below the grooved ball bearing. Refer to => [ Grooved Ball Bearing Changes ] Service and Repair.
• 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 (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.
• 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
- Install circlip - 1 - for grooved ball bearing/input shaft.
- Remove (30-211A) for input shaft.
- If selector shaft lock sleeve has been removed, drive it in now as far as stop on tool => [ Lock Sleeve Differentiation ] Transmission Housing.
- 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 - 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 elbow - arrow - must not be installed when doing so.
- Install back-up light switch (F4) - 1 -.
- Install the flange shaft with spring, the thrust washer and tapered ring.
- Drive input shaft seal in flush.
- Install the clutch slave cylinder with release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Service and Repair.
- Shift through all gears.
- Drive the cap into the transmission housing as far as the stop.
- Secure the cap with the circlip - A -.
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.
- Bring right drive axle splines and differential bevel gear also into alignment, rotate flanged shaft if necessary.
- 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.