Disassembling Transmission - GT2
343537 Disassembling Transmission - GT2Tools
Removing transmission cover
1. Remove transmission.
2. Fasten the transmission on assembly support.
3. Drain transmission oil.
4. Remove electric cable.
5. Remove hose -A- between oil cooler and transmission housing.
6. Remove oil cooler. To do this, undo screws -B- and lift oil cooler up and off.
7. Remove the oil pump. To do this, remove screws. Screw in special tool threaded piece vw 771/15 in thread -A-. Drive oil pump up and out with special tool striker vw 771.
8. Unscrew fastening screws for front transmission case cover and force transmission case cover off with a rubber hammer if necessary.
Disassembling front gear set
Overview
Disassembling gear set
1. Remove transmission cover.
2. Fix the transmission with special tool retaining device 9253 and shift into a gear.
3. Remove nut -A- on input and output shaft.
4. Unscrew clamping screw from shift forks -B-.
5. Remove fixed gearwheel for reverse gear (no. 33 in overview) from the input shaft using the puller and special tool pressure pieces 9656. When doing so, pull off bearing inner race (no. 32 in overview).
6. Remove spacer sleeve (no. 34 in overview) from the input shaft.
7. Remove loose gearwheel for reverse gear (no. 4 in overview) with needle-roller bearing (no. 6 in overview) from the output shaft using the puller and special tool pressure pieces 9656. When doing so, also pull off the cylindrical-roller bearing (no. 2 in overview) and thrust plates (no. 3 in overview).
8. Push complete gear set forwards onto output shaft using two mounting levers 1 - 2 cm.
9. Push gear set back behind the bearing inner race (no. 7 in overview) and remove bearing inner race using the puller and special tool pressure pieces 9656.
10. Open up shift fork and remove complete synchronization.
11. Remove fixed gear wheel, 5th gear (no. 35 in overview) and the spacer sleeve (no. 34 in overview).
12. Remove loose gearwheel, 5th gear (no. 16 in overview) with needle-roller bearing (no. 18 in overview).
13. Remove bearing inner race using puller and special tool pressure pieces 9656.
14. Open up shift fork and remove complete synchronization.
15. Remove loose gearwheel, 6th gear (no. 27 in overview) with needle-roller bearing (no. 28 in overview).
16. Remove bearing inner race (no. 29 in overview) using puller and special tool pressure pieces 9656
17. Remove thrust plate (no. 30 in overview).
Removing gear housing
1. Remove transmission cover.
2. Disassembling front gear set.
3. Unscrew screw -A- and remove oil tube -B-.
4. Unscrew fastening screws between gear housing and transmission and remove studs.
5. Unscrew plug screw -C- and remove the spring with locking pins.
6. If necessary force gear housing off with a rubber hammer.
Removing input and output shaft
Overview
Removing shafts
1. Unscrew screw plugs (no. 33 in overview) of the locking elements and remove springs (no. 34 in overview) and ball (no. 35 in overview).
2. Pull out reverse gear shift rod (no. 26 in overview) and shift rods for 5th/6th gear (no. 28 in overview) towards the front. Pay attention to the intermediate lock (no. 25 in overview) and locking elements (no. 23 in overview) during this procedure.
3. Remove differential lock.
4. Remove oil tube (no. 22 in overview).
5. Remove cylindrical-roller bearing (no. 32 in overview) from input shaft using a puller.
6. Pull loose gearwheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no. 2 in overview) and cylindrical-roller bearing (no. 1 in overview).
7. Pull off the fixed wheel for 3rd gear (no. 21 in overview) with synchronization 1st/2nd gear (no. 16 to 4 in overview) and loose gearwheel for 2nd gear (no. 17 in overview).
Note:
^ A specific disassembly of the synchronization in assembled state may be recommendable as loss of the small parts can then be avoided.
8. Unscrew nuts (no. 30 in overview) and remove tensioning plate (no. 29 in overview) with shafts and remaining gearwheels.
9. Remove drive wheel of the oil pump (no. 38 in overview) and fixed wheel for 4th gear (no. 39 in overview) and take output shaft out of the tensioning plate.
Disassembling output shaft
Overview
Disassembling shaft
1. Remove adjusting shim (no. 1 and 2 in overview) from shaft. Note the quantity and thickness for reinstallation.
2. Press cylindrical-roller bearing (no. 6 in overview) off with bearing inner race (no. 5 and 3 in overview) and four-point bearing (no. 4 in overview).
Dismantling input shaft
Overview
Disassembling shaft
1. Clamp complete shaft into the vice with gear set and special tool socket wrench insert 9282.
2. Remove fastening nut.
3. Press off loose gearwheel for 3rd gear (no. 20 in overview) with synchronization (no. 11 to 19 in overview), loose gearwheel for 4th gear (no. 10 in overview) and the remaining parts (in overview 2 to 9).