Disassembling and Assembling Transmission

Disassembling and assembling transmission
Tools








Preliminary work

1. Remove transmission.





2. Tighten the transmission using engine support 9589 or engine and gear support VW 540 at the assembly support.
3. Drain transmission oil.
4. Remove sealing ring for drive shaft.

Disassembling transmission
Removing transmission housing








Removal instructions for transmission housing









1. Drive ball bearing -7- out of the housing with taper roller bearing puller, Boxster manual transmission NR.119.

Removing transmission cover








Removal instructions for transmission cover





1. Pull out drive shaft -A-, output shaft -B-, deflection rod -C-, shift rods -D- and shift fork -E- together.

Assembling transmission
Fitting transmission cover








Installation instructions for transmission cover





1. Place drive shaft and output shaft together and insert into the transmission housing.





2. Insert relay shaft and interior shift rod.
- Shift into 3rd gear.
- Insert relay shaft.
- Place interior shift rod next to the guide bore of the bearing cover.
- Slide the shift finger into the driver of the relay shaft and swivel this carefully into the guide bore by turning the interior shift rod.
3. Install switch interlock.
- Put the interlock slide into the centre position.
- Shift into neutral.
- Insert switch interlock.
- Latch relay shaft into switch interlock.
- Secure switch interlock with Torx screw with collar.





4. Insert and tighten screws for relay shaft.





5. Seal transmission cover with Loctite 574 and fit it. Ensure correct position of dowel sleeves in transmission housing. See - Rep. Gr. 343737 Disassembling and assembling transmission housing

Fitting transmission housing








Installation instructions for transmission housing





1. Press in ball bearing for the drive shaft.
- Place thrust washer -A- of the press-in device 3235 onto the ball bearing.
- Position press-in device 3235 behind the toothing for the clutch plate on the drive shaft and pretension with both screws -B-. The screws are supported in the two lowered areas of the thrust washer.
- Press in the ball bearing as far as it will go by alternately tightening the screws -B- (tighten only in 1/2 turns to avoid tilting and thus damaging the ball bearing).

Subsequent work

1. Install sealing ring for drive shaft.
2. Fill with transmission oil.
3. Remove transmission from assembly support.
4. Install transmission.