Transmission Cover
Transmission Cover
Special tools, testers and auxiliary items required
• Drift (VW 207 C)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Punch (VW 411)
• Thrust Disc (VW 412)
• Tube 28 mm Dia. 210 mm (VW 420)
• Sleeve (VW 423)
• Arbor (VW 434)
• Thrust Ring (VW 470)
• Sleeve (VW 472/2)
• Guide Bolt (10 - 15)
• Drift Sleeve (40-20)
• Thrust Pad (3005)
• Thrust Pad (3062)
• Extension (3161)
• Guide Bearing Inst. Tool (3347)
• Shock Absorber Set (T10001)
• Pulling Hook (T20143)
• Drift (T40085)
• Internal Puller 56 to 110 mm , for example, (Kukko 21/89)
• Counter-Support , for example, (Kukko 22/4)
• Sealing paste (AMV 188 001 02)
• Sealing grease (G 052 128 A1)
• Locking fluid (AMV 185 101 A1)
1 Large Securing Bushing
• For the gearshift shaft
• Removing and installing, refer to => [ Removing and Installing the Large Locking Bushing on the Gearshift Shaft ]
• Installed dimension, refer to => [ Installed Dimension for the Large Locking Bushing Inside the Transmission Cover ]
2 Securing Bushing
• For the gearshift rail / shift fork
• Removing and installing is currently not possible.
3 Needle Bearing
• For the output shaft/drive gear mounting
• Removing, refer to => [ Remove the Needle Bearing from the
Transmission Cover ]
• Always replace
• Installing, refer to => [ Installing the Needle Bearing All the Way into the Transmission Cover ]
• Secure after installing with peen, refer to => [ Securing the Needle Bearing Inside
the Transmission Cover by Peening It ]
4 Outer Race/Tapered Roller Bearing
• For mounting the impeller wheel/drive gear in the transmission cover
• Removing, refer to => [ Pressing Tapered Roller Bearing Outer
Race Out from the Transmission Cover ]
• Installing, refer to => [ Installing the Outer Race / Tapered
Roller Bearing All Way into the Transmission Cover ]
5 Transmission Cover
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
6 Oil Fill Plug
• 40 Nm
7 O-ring
• Installed only on transmissions with a cover / gearshift shaft together with a transmission neutral position sensor (G701) or cap
• Always replace
8 Cover
• For the gearshift shaft together with a transmission neutral position sensor (G701) or a cap
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Selector shaft seal, removing and installing, refer to => [ Gearshift Shaft Seal, Removing and
Installing ]
• Remove the gearshift shaft ball sleeve, refer to => [ Removing the Gearshift Shaft Ball Sleeve
from the Cover ]
• Install the gearshift shaft ball sleeve, refer to => [ Installing the gearshift Shaft Ball
Sleeve Up to Dimension into
the Cover. ]
9 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
10 Bolt
• 24 Nm
• Steel bolts (M8; 25 mm long)
• Insert with locking fluid (AMV 185 101 A1)
11 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 (G701) , allocate according to the transmission code, refer to the electronic parts catalog ETKA
12 Cover
• For the gearshift shaft without a transmission neutral position sensor (G701) or a cap
• Not present on all versions
• Allocate according to transmission code, refer to the electronic parts catalog ETKA
• Removing and installing, refer to => [ Removing and Installing the Gearshift
Shaft Cover ]
• Assembly Overview => [ Gearshift Shaft Cover Assembly Overview ]
• Selector shaft seal, removing and installing, refer to => [ Gearshift Shaft Seal, Removing and
Installing ]
• Remove the gearshift shaft ball sleeve, refer to => [ Removing the Gearshift Shaft Ball Sleeve
from the Cover ]
• Install the gearshift shaft ball sleeve, refer to => [ Installing the Gearshift Shaft Ball
Sleeve Evenly in the Cover ]
13 Bearing Bushing
• For the 3rd/4th gear gearshift rail / shift fork
• Removing, refer to => [ Removing the Bearing Bushing for the
3rd and 4th Gear Gearshift Rail / from the Transmission Cover ]
• Installing, refer to => [ Installing the Bearing Bushing for the 3rd and 4th Gear Gearshift Rail / Shift Fork
All the Way into the Transmission Cover ]
14 Small Locking Bushing
• For the gearshift shaft
• Removing and installing is currently not possible.
15 Ventilation Pipe
• Installed dimension: 17.5 mm ± 0.5 mm from the upper edge of the pipe on the housing
• Unclip the transmission breather cap
16 Cap
• For the transmission ventilation
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. Refer to => [ Installed Dimension for the Large Locking
Bushing Inside the Transmission Cover ].
Installed Dimension for the Large Locking Bushing - 1 - Inside the Transmission Cover
- Use a depth gauge - 2 - to check the installed dimension - a - = 5 ± 0.2 mm.
• Insert the depth gauge on the first shoulder - arrow - of the locking bushing.
Remove the Needle Bearing from the Transmission Cover
A Counter-support , for example, (Kukko 22/4)
B Internal puller 56 to 110 mm , for example, (Kukko 21/89)
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 (3062).
- Secure needle bearing after pressing into transmission cover with peen. Refer to => [ Securing the Needle Bearing Inside
the Transmission Cover by Peening It ].
Securing the Needle Bearing Inside the Transmission Cover by Peening It
- To peen, use blunt center punch with ball-shaped end (ball 5 mm diameter).
- Needle bearing is secured with 3 peening marks on circumference every 120° - arrows -.
Pay special attention to the position and the diameter of the peen points:
• - 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 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.
- Clean screw threads with a wire brush.
- Apply the sealing compound (AMV 188 001 02) evenly on the sealing surface on the sealing cover.
- Install the sealing push-in cap while installing the bolts using locking fluid (AMV 185 101 A1) and tighten down to the specified torque. Refer to => [ (Item 10) Bolt ].
Gearshift Shaft Cover Assembly Overview
1. Selector shaft seal, removing and installing, refer to => [ Gearshift Shaft Seal, Removing and
Installing ]
2. Cover
3. Gearshift shaft ball sleeve, removing, refer to => [ Removing the Gearshift Shaft Ball Sleeve
from the Cover ] and Installing => [ Installing the Gearshift Shaft Ball
Sleeve Evenly in the Cover ]
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, refer to => [ Gearshift Shaft Seal, Removing and
Installing ]
2. Cover
3. Gearshift shaft ball sleeve, removing, refer to => [ Removing the Gearshift Shaft Ball Sleeve
from the Cover ] and Installing => [ Installing the gearshift Shaft Ball
Sleeve Up to Dimension into
the Cover. ]
4. O-ring
Gearshift Shaft Seal, Removing and Installing
- Pry out the shaft seal using the pulling hook (T20143/1).
- Lightly coat the outer circumference of the shaft seal with oil.
- Fill the space between the sealing- and dust lip half way with sealing grease (G 052 128 A1).
- Install the shaft seal using the (T10001/1) or the (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 guide pin (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).