Through Build Date, 18 May 2003

Transmission Housing From Build Date, 19 May 2003

Special tools and workshop equipment required
- Punch -VW 407-
- Tube 37mm Dia. -VW 416 B-
- Slide Hammer-Complete Set -VW 771-
- Holding Fixture -VW 801-
- Centering Mandrel -12-551-
- Seal Driver -3129-
- Centering Mandrel -3176-
- Kukko Extractor 23.5-30mm -21/4-
- Kukko Extractor 14.5-18.5mm -21/2-
- Kukko Support -22/2-







1. Transmission Housing
- When replacing: adjust the output shaft and differential.

2. Seal
- Always replace, if equipped.

3. Oil Drain, Plug
- 30 Nm
- Always replace.

4. Retaining Sleeve
- Removing, please see Retaining Sleeve, Removing in this procedure.
- Installing, please see Retaining Sleeve, Installing in this procedure.

5. Oil Fill, Plug
- 30Nm
- Always replace.

6. Locking Pin
- Push the shift unit into the slotted guide rail to adjust the shift unit.
- Removing, please see Locking Pin, Removaing in this procedure.
- Installing, please see Locking Pin, Installing in this procedure.

7. Bushing
- For the selector shafts.
- Replace after removing.
- Removing, please see Selector Shaft Bushing, Removing in this procedure.
- Installing, please see Selector Shaft Bushing, Installing in this procedure.

8. Needle Sleeve
- For the reverse shaft, replace after removing.
- Removing, please see Needle Sleeve, Removing in this procedure.
- Installing, please see Needle Sleeve, Installing in this procedure.

9. Adjusting Shim
- For the input shaft.

10. Outer Race/ Tapered Roller Bearing
- For the input shaft.
- When replacing: adjust the input shaft.

11. Outer Race/ Tapered Roller Bearing
- Output shaft, 5th, 6th and reverse gears.
- When replacin: adjust the output shaft for 5th/ 6th and reverse gears.

12. Adjusting Shim
- Output shaft, 5th, 6th and reverse gears.

13. Outer Race/ Tapered Roller Bearing
- Output shaft, 1st to 4th gears.
- Adjust, if the output shaft for 1st to 4th gears is replaced.

14. Adjusting Shim
- Output shaft, 1st to 4th gears.

15. Outer Race/ Tapered Roller Bearing
- For the differential
- When replacing: adjust the differential.

16. Adjusting Shim
- For the differential

17. Seal

Retaining Sleeve, Removing






Retaining Sleeve, Installing






- Install the retaining sleeve using a 13mm socket -A- and a plastic hammer.

Locking Pin, Removing






Locking Pin, Installing






Selector Shaft Bushing, Removing






A - Internal puller 14.5 to 18.5mm, for example -21/2-
B - Counter support, for example, -22/2-

Selector Shaft Bushing, Installing






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






- While installing, place the thrust washer -B- for the reverse shaft on to the needle sleeve -A-.
- Support the transmission housing beneath the bearing mount using -VW 416B-.