From Build Date, 19 May 2003
Transmission Housing From Build Date, 19 May 2003
Special tools and workshop equipment required
- Driving Sleeve -VW 244B-
- Transmission Support -VW 353-
- Thrust Plate -VW 401-
- Thrust Plate -VW 401-
- Punch -VW 407-
- Tube 37 mm Dia. -VW 416B-
- Guide Pin -VW 436A-
- Guide Pin -VW 439-
- Slide Hammer -Complete Set- -VW 771-
- Holding Fixture -VW 801-
- Guide Bolt -10-15-
- Thrust Pad -3124-
- Bearing Driver -3264-
- Subframe Support Assem. Device -3290-
- Torque Wrench (5-50Nm) -V.A.G 1331-
- Drift -T10168-
- Drift -T10169- or -T10362-
- Thrust Piece -T10203-
- Kukko Extractor 14.5-18.5 mm -21/2-
- Kukko Extractor 23.5-30 mm -21/4-
- Kukko Support -22/2-
1. Transmission Housing
- When replacing: adjust the output shaft and differential.
- From build date 10 April 2006, changed in grooved ball bearing/ input shaft mount area
2. Cover
- Removing, please see
- Installing, please see
3. Oil Drain Plug
- There are different versions, please see
- With a internal multi point - 45 Nm.
- With a internal hex - 30 Nm.
4. Seal
- Always replace, if equipped.
5. Fluid Fill Plug
- There are different versions, please see
- With a internal multi point - 45 Nm.
- With a internal hex - 30 Nm.
6. Locking Elbow
- For adjusting the shift unit.
- Can be replaced with the transmission not disassembled.
- Removing, please see
- Installed position, please see
- Installing, please see
7. Bushing
- For the selector shafts
- Removing, please see
- Installing, please see
8. Retaining Sleeve
- Removing when the transmission is disassembled, please see
- Removing when the transmission is not disassembled, please see
- Different retaining sleeves, please see
- Installing a retaining sleeve with a shoulder, please see
- Installing a retaining sleeve without a shoulder, please see
9. Needle sleeve
- For the reverse shaft
- Replace after removing
- Removing, please see
- Installing, please see
10. Outer Race/ Tapered Roller Bearing
- Output shaft, 5th, 6th and reverse gears.
- When replacing: adjust output shaft for 5th/ 6th and reverse gear.
11. Adjusting Shim
- For the output shaft for 5th/ 6th gears.
12. Outer Race/ Tapered Roller Bearing
- Output shaft, 1st to 4th gears.
- Adjust, if the output shaft for 1st to 4th gears is replaced.
13. Adjusting Shim
- Output shaft, 1st to 4th gears.
14. Outer Race/ Tapered Roller Bearing
- For the differential.
- When replacing: adjust the differential.
15. Adjusting Shim
- For the differential.
16. Bushing
- For the shift unit.
- Removing, please see
- Installing, please see
17. Plug
- Removing, please see
- Installing, please see
18. Seal
Cover, Removing
- Pierce the rubber cover -A- in the center with a screwdriver -B- and pry it out in the -direction of the arrow-.
Cover, Installing
Oil Fill and Drain Plugs, Different Versions
- I - Oil fill or drain plug with a multi point socket head.
- II - Oil fill or drain plug with a hex socket head.
Locking Elbow for the Shift Unit, Removing
- Remove the elbow in its unlocked position.
- Guide a screwdriver -A- into hole of lock elbow -B-.
- Pry out the locking elbow in the -direction of the arrow-.
Locking Elbow, Installed Position
- The mark on the locking elbow -arrow- must point towards the connection on the clutch slave cylinder -1-.
Dimension -a- must be approximately 45°.
Drive the Shift Unit Lock Elbow -arrow- in Up to The Tool Shop
NOTE:
The locking elbow must be unlocked when being installed.
Selector Shaft Bushing, Removing
A - Internal Puller 14.5 to 18.5 mm, for example, -21/2-
B - Counter Support, for example, -22/2-
Selector Shaft Bushing, Installing
Retaining Sleeve, Removing
- Position, the transmission housing on the -VW 401- and the -VW 402- so that the retaining sleeve -A- inside the transmission housing does not get damaged.
Retaining Sleeve, Removing, Transmission not Disassembled Using -10-15-
- Remove the retaining sleeve and shift unit.
- Turn the transmission so that the retaining sleeve cannot fall into the transmission.
Retaining Sleeve Differentiation
A retaining sleeve with a shoulder -arrow 1-
A retaining sleeve without a shoulder -arrow 2-
Drive in Retaining Sleeve with Shoulder as Far as the Stop on Tool
- The transmission housing is bolted to the clutch housing.
Drive in Retaining Sleeve without Shoulder as Far as the Stop on Tool
- The transmission housing is bolted to the clutch housing.
Needle Sleeve, Removing
A- Internal puller 23.5 to 30mm, for example, -21/4-
B- Counter support, for example, -22/2-
NOTE:
The needle sleeve will get damaged when it is removed and must be replaced.
Needle Sleeve, Installing
- Place the thrust washer -B- for the reverse shaft onto the needle sleeve -A-.
- Support the transmission housing beneath the bearing mount using -VW 416 B-.
Selector Shaft Bushing, Removing
- Hold the spindle on the -3290- and turn the nut -B-.
A- Internal puller 14.5 to 18.5mm, for example, -21/2-.
Shift Unit Bushing -A-, Installing
Plug -1-, Removing
- Remove the plug -1- from the inside of the transmission housing toward the outside.
Plug -1-, Installing
- Using -3264-, drive in the plug to dimension -a- approximately 3mm below the upper edge of the housing.