Transmission Without Cap/Input Shaft Retaining Ring Assembly Sequence
Transmission without Cap/Input Shaft Retaining Ring Assembly Sequence
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Pressing Sleeve (VW 455)
• Slide Hammer (VW 771)
• Internal Puller (Kukko 21/01)
• Separating Tool (Kukko 17/0)
• Counter-Support (Kukko 22/1)
• Bracket (30-211A)
• Thrust Piece (T10042)
• 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
Removing
- Secure transmission to assembly stand with bolts - arrows -.
• If one of the fastening holes does not contact the Transmission Support , place shims between fastening hole and Transmission Support.
- Rotate transmission in assembly stand with oil drain plug downward.
- Place drip tray underneath.
- Drain gear oil.
- Remove slave cylinder with release bearing - arrows -.
In the following step, ensure selector shaft is not locked by the lock elbow - arrow -.
- Move shift shaft to neutral position.
- Remove mounting bolt - 2 -.
- Then remove bolts - 3 -.
- Remove back-up lamp switch (F4) - 1 -.
- Pull selector shaft - 4 - off transmission housing.
- Remove flanged shaft and stub shaft.
As of transmission build date 01 11 4, the right stub shaft was replaced by a flange shaft.
Allocation, refer to the Parts Catalog.
- Remove bolts - B - inside clutch housing for securing clutch housing to transmission housing.
• One bolt - arrow - is located outside of bolting flange.
- Secure input shaft by inserting pressing sleeve (VW 455) over input shaft onto clutch housing.
- Then tension separating tool - A -, for example (Kukko 17/0) tightly behind input shaft splines.
During this, 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 grooved ball bearing of input shaft/transmission housing as follows:
- Hold one end of circlip in place using Screwdriver - A -.
- Using Screwdriver - B -, pry other end out of groove for grooved ball bearing in direction of - arrow -.
- By repositioning Screwdriver - B -, pry the circlip out further.
- If present, remove washer - 1 - from transmission housing - 2 -.
• If transmission is replaced, check whether washer must be reinstalled.
- Remove mounting bolts - A - for transmission housing at clutch housing.
- Screw Adapter VW 771/40 into threaded hole of transmission housing.
- Heat transmission housing using (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to 100 °C / 212 °F for approximately 10 minutes.
- Remove transmission housing from clutch housing using slide hammer (VW 771/1) in direction of - arrow -.
• If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.
- If present, remove washer - 1 - from grooved ball bearing - 2 -.
- If transmission is replaced, check whether washer must be reinstalled.
- Remove Separating Tool - A - and Pressing Sleeve 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 (30-21).
• Grooved ball bearing on input shaft must always be replaced => [ (Item 8) Input Shaft ] Input Shaft Overview.
Installing
• A new grooved ball bearing must be pressed on to input shaft => [ (Item 8) Input Shaft ] Input Shaft 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 -.
- Then 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 output shaft for 1st to 4th gears in - direction of arrow -.
• Splines of input shaft, output shafts and final drive gear/differential must engage.
- Together with a second technician, now displace shafts and differential in 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.
From transmission build date 4.10.06 through approximately 1.21.08
One washer each is inserted above and below input shaft grooved ball bearing.=> [ (Item 8) Input Shaft ] Input Shaft Overview
- Check transmission housing.
- Measure shoulder above grooved ball bearing mount.
The area below the grooved ball bearing seat in the transmission housing has been changed.
Place a washer (85 mm outer diameter) - 1 - on the grooved ball bearing - 2 -.
Check the transmission housing and grooved ball bearing.
The Grooved Ball Bearing/Input Shaft Fits Inside the Transmission Housing in only Position on some Transmissions
There is a flattened area on the grooved ball bearing and the bearing mount.
• If flattened areas - A - and - B - are present, then do not install the washers.
• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.
- Mark the flattened side 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 (see next illustration).
- Heat transmission housing using Heat Gun (V.A.G 1416) in area of bearing seat for grooved ball bearing/input shaft to 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.
• Align the marking on the grooved ball bearing - A - with the marking on the transmission housing - B - and mount the transmission 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
From Transmission Build Date 10 04 6 through 20 1 8, a Washer - 1 - (Outer Diameter = 78.6 mm) was Installed Above the Grooved Ball Bearing - 2 -.
See if a washer - 1 - must be placed above the grooved ball bearing - 2 -. Refer to => [ Grooved Ball Bearing Changes ] Grooved Ball Bearing Changes
- Install circlip - 1 - for grooved ball bearing/input shaft.
- Remove Bracket (30 - 211 A) for input shaft.
- If selector shaft lock sleeve has been removed, drive it in now as far as stop on tool. Refer to => [ 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 - 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 screw - 2 -, lock elbow - arrow - must not be installed when doing so.
- Install back-up lamp switch (F4) - 1 -.
- Install flanged shaft and stub shaft with compression springs, thrust washers and tapered rings.
As of transmission build date 01 11 4, the right stub shaft was replaced by a flange shaft.
Allocation, refer to the Parts Catalog.
- Drive input shaft seal in flush.
- Install slave cylinder with release bearing => [ Clutch Slave Cylinder with Release Bearing ] Service and Repair.
- Shift through all gears.
- Drive the cap into the transmission housing as far as the stop.
