Through Build Date, 18 May 2003
Transmission Disassembly and Assembly Through Build Date, 18 May 2003Special Tools and workshop equipment required
- Holding plate -VW 309-
- Holding Fixture -VW 313-
- Transmission Support -VW 353-
- Sleeve -30-21-
- Thrust Piece -T40008-
- Torque Wrench (5-50Nm) -V.A.G 1331-
- Torque Wrench (40-200Nm) -V.A.G 1332-
- Hex Extension -V.A.G 1669-
Disassembling
- Attach the transmission to the assembly stand with bolts -arrows-.
- Turn the transmission in the assembly stand so that the drain plug is facing down.
- Place a drip tray underneath.
- Drain the transmission fluid from the transmission and bevel box.
- Remove the right flange shaft bolt using the -V.A.G 1669- or a 6mm socket.
NOTE:
The right flange shaft in the bevel box.
- Remove the four bevel box to transmission bolts -arrows- (only three are shown in the illustration).
- Remove the bevel box from the transmission.
- Remove the clutch slave cylinder with release bearing bolts -arrows- and slave cylinder.
- Remove the backup lamp switch -1-.
- Remove the bolts -2- for the shift unit cap -A-.
- Carefully remove the cap.
- Remove the bolt -3-.
- Remove the bolts -4- and remove the shift unit cover -B-.
- Remove the shift unit in the -direction of the arrow- from the transmission housing.
- Remove the left flange shaft.
- Remove the transmission housing the differential housing bolts -A-.
- Remove the clutch housing the transmission housing bolts -B-.
NOTE:
The bolt -arrow- is located outside of the bolting flange. It is installed with a washer.
- Remove the transmission housing. If necessary, carefully pry up all around and alternate between sides on the protruding flange. Be careful not to damage the sealing surfaces.
From Build Date 06 April 2000
- Remove the bolt -arrow- for the securing plate (input shaft outer race/tapered roller bearing).
- Remove the securing plate.
- Move the input shaft in the -direction of the arrow- and remove it.
- Remove the speedometer vehicle speed sensor.
- Together with a second technician, remove the differential -1-, the output shafts -2 and 3-, the reverse gear shaft -4- and the shift forks -5- carefully from the clutch housing.
- Remove the input shaft seal using the -30-21-.
Assembling
- Install the differential -1-.
- Install the 5th/ 6th gear output shaft and the reverse gear -2- together with the reverse gear shift fork, the 5th/ 6th gear shift fork -3- and the reverse gear shaft -4-.
- Hold the output shaft for 1st through 4th gear -3- and the shift forks -5- with the right hand.
- Slightly lift the differential with the left hand.
- Have the second technician lift the 5th/ 6th gear output shaft and reverse gear -2- together with the reverse gear shaft -4- slightly at the same time.
- Install the 1st to 4th gear output shaft in the -direction of the arrow-.
The splines on the output shafts and the final drive/ differential must engage.
- Together with a second technician, now place the shafts in their bearing seats.
- Install the input shaft into the clutch housing -arrow-.
From Build Date 06 April 2000
- Install the securing plate -arrow- and a new bolt into the notch in the outer race/ tapered roller bearing for the input shaft.
- Tighten the new bolt to specification, see item 11.
- Install the transmission housing.
Install the shift unit as follows:
- Move the selector forks into the neutral position.
- Install the shift unit -1-.
- Position the shift unit so that the fingers fit into the selector rods.
- Align the cap -A- with an M8 x 60mm bolt -2- to the lower bearing on the shift unit -1-.
- Install and tighten the bolts -arrows- for the cap -A- alternating from side to side hand tight (1/2 Turn).
- Remove the bolt -2- and install an original bolt in its place hand tight.
- Install the shift unit cover -B- and tighten the bolts -4- to specification.
- Tighten the bolts for the cover.
- Install the bolts -3- for the shift unit with locking fluid -D 000 600 A2-.
- Install the backup lamp switch.
- Install the left flange shaft and pressure spring, the thrust washer and the tapered ring.
- Install the speedometer vehicle speed sensor.
- Install the input shaft seal using the -T40008-.
- Install the clutch slave cylinder and release bearing.
Install the bevel box as follows:
- Always replace the O-ring for sealing the bevel box/ transmission -arrow A- and the O-rings for sealing the sleeves -arrows B and C-. Lubricate the O-rings lightly with oil.
- Lubricate the differential splines with grease for clutch disc shaft splines -G 000 100-.
- Slide the bevel box completely onto the manual transmission, while doing this, join the splines of the input shaft/ bevel box centrally with connecting sleeve/ differential.
- Bring the right drive axle splines and the differential bevel gear into alignment. Rotate the flange shaft if necessary.
- With proper tooth position and central guiding, the bevel box slips up to the stop against the manual transmission.
- Do not pull the bevel box with the bolts against manual transmission, otherwise bevel box is tilted and mounting eyelets can break off.
- Install the four bevel box to transmission bolts -arrows- (only three are shown in the illustration).
- Tighten the bolt for the right flange shaft using the -V.A.G 1669- or a 6mm socket while counter holding the flange shaft with a drift.