Transmission

Transmission

=> [ 5th Gear, Installing ]

Special tools, testers and auxiliary items required

• Holding Plate (VW 309)

• Transmission Support (VW 353)

• Needle Bearing Drift (VW 295)

• Driving Sleeve (VW 244 B)

• Hot Air Blower (V.A.G 1416)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• M8 x 100 mm Bolt

• Bracket (30-211A)

• Driving Sleeve (32 -111)

• Thrust Piece (T10030/4)

• Tube 37 mm Dia. (VW 416 B)

• Puller (T10408)

• M7 x 35 Bolts with Washers

• Kukko Puller 65-160 mm (Kukko 18/1)

• Support Bridge (T10323)

• Wheel Bearing Assembly Set (3253/7)

• Thrust Pad Con. 8/65 (VW 433)

• Torque Wrench (40-200 Nm( (V.A.G 1332)

Removing

- Remove the clutch release lever, the release bearing and the guide sleeve. Refer to => [ Clutch Release Mechanism ] Service and Repair.

• Be careful not to damage the bearing for the input and output shafts when removing and installing 5th gear.

• When securing the transmission to the transmission support (VW 353), mount the following tools for support:

Under the Input Shaft:

• Bracket (30-211A)

• Driving sleeve (32 - 111)

• Thrust piece (T10030/4)

- Secure the bolt on the bracket (30-211A) with the nut - A -.

Under the Output Shaft Bracket:

• Support bridge (T10323)

• (3253/7) from the wheel bearing assembly set

• Thrust pad con. 8/65 (VW 433)

- Secure the transmission on the transmission support (VW 353).

- Place the drip tray (V.A.G 1306) underneath.

- Open the oil filler plug and the oil drain plug.

- Drain the transmission fluid.

- Remove the transmission housing cover - arrow -.

Remove the 5th gear selector fork as follows:

- Cover the openings with a cloth.

- Move the selector fork - 1 - into neutral.

- Remove the bolt - 2 - for the 5th gear shift jaw.

- Remove both bolts - arrows - for the selector fork bases.

- Remove the selector fork bases.

- Remove the selector fork.

- It is not necessary to remove the spring - 3 - and the locking collar - 4 -.

- Engage 5th gear - arrow 1 - and 1st gear - arrows 2 and 3 - and then remove the bolts - A - for the synchronizing hub with operating sleeve and for the 5th gear.

- The input and output shafts are blocked after engaging both gears, the synchronizer hub and the toothed gear cannot turn. Both bolts can be loosened now.

• Remove any locking compound residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.

- Remove both bolts - arrows - for the reverse gear shaft support.

- Remove the 3rd bolt - arrow - for the reverse gear shaft support.

- Transmission on vehicles with a stop/start system: remove the transmission neutral position sensor (G701) - arrow -.

- Move the gear shift unit into neutral and remove the gear shift unit with the shift cover. Remove the bolts - arrows - and pull the gear shift nit out of the transmission housing.

- Remove the sealing cap - A - and support pins - B - from the bottom of the transmission.

- Remove the support pins - A - from the top side of the transmission and remove the bolts - B - for the transmission housing to clutch housing in the area of the differential.

- Remove the bolts - A - that connect the clutch and transmission housing.

• Do not remove the nuts - B - for the bearing mount on the output shaft.

- Remove both flange shafts.

- Remove the flange shafts with the springs, thrust washers and tapered rings.

Remove the following components together with the transmission housing:

• 5th gear synchronizing hub with operating sleeve

• 5th gear

• Both straps (T10408/3) must be attached to the 5th gear.

• The straps (T10408/3) must be located above the 2 ribs on the housing, opposite each other - arrows -.

• There is a needle bearing under the 5th gear.

• Secure the straps (T10408/3) so that the needle bearing does not touch the 5th gear when removing the transmission housing.

Use puller (T10408) together with the following special tools:

• Pressure pieces (T10408/2)

• Straps (T10408/3)

• Kukko Puller 65-160 mm (18/1)

- Secure the plate (T10408) in the threaded holes in the transmission housing cover.

A M7 x 35 bolts with washers

Tightening specification: 18 Nm

- Place the Pressure pieces (T10408/2) on the shafts.

- Install the Kukko puller 65-160 mm (18/1) - A -.

- Remove the 5th gear synchronizing hub with operating sleeve, the 5th gear and the transmission housing by tightening the spindles - A - - (approximately 1/2 turn).

- Warm the 5th gear slightly using the hot air blower (V.A.G 1416).

- Remove the selector forks - A - with the rails.

- Remove the shift mechanism/reverse gear - B -.

- Remove the nuts - B - from the bearing mount/output shaft.

- Remove the reverse gear - A -, the input shaft - B - and the output shaft - C -, one after the other, from the clutch housing.

- Remove the differential.

Assembly

- Install the differential.

- Always replace the seals - arrows - for the bearing mount/output shaft.

• The illustration only shows 3 of the 4 seals.

- Insert the input shaft - 1 - and output shaft - 2 - together.

- Tighten the output shaft bearing mount nuts, see - item 11 - in => [ Input Shaft, Output Shafts, Differential and Shift Forks ] Transmission Component Overviews to specification.

- Place the reverse gear drive gear - 3 - on needle bearing in clutch housing.

The shoulder - arrow - faces away from the clutch housing.

- Make sure the reverse shaft - 4 - is complete, refer to => [ Reverse Shaft ] Reverse Shaft ; do not mount the support on the reverse shaft.

- Install the reverse shaft into the clutch housing.

- Clean all threaded holes in the reverse shaft supports of locking compound; cleaning can be done with a thread tap.

- Mount the reverse gear shaft support.

- Install the reverse gear selector fork - 1 - with the support for the reverse gear shaft - 2 -, the spring - 3 - and the sliding piece - 4 -.

Reverse gear location

- Install the shift mechanism/reverse gear - A -.

- Install the selector forks - B - together with the rails.

Reverse gear supports - C - are located in front of the selector rails.

- Install M 8 x 100 mm studs - A - into the reverse gear shaft support so that the shaft is aligned after fitting the transmission housing.

- Align the selector rails.

• The shift segments must be installed in the grooves on the locking collars.

- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.

- Install the transmission housing.

Install the bolts for the reverse gear shaft support - arrow - as follows:

- Install the bolt - a -.

- Remove the stud bolt - A - (⇒ upper illustration).

- Install the bolt - c -.

Tightening sequence:

- Tighten the bolt - a - to 30 Nm.

- Tighten the bolt - b - (⇒ lower illustration) to 25 Nm.

- Tighten the bolt - c - to 25 Nm.

- Install the support pin - arrow - for the selector forks. To do this align the shift mechanism using a screwdriver, so that the relevant support pin can be installed.

- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the sealing cover.

- Install the gear shift unit.

Install the gearshift shaft cover as follows:

- Move the gear shift unit into the neutral position.

- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the cover.

- Move the gear unit into neutral.

- Position the selector shaft so that selector finger - arrow - is inserted into the selector rails.

- Tighten the gear shift unit cover bolts to specification, see - item 17 - in => [ Transmission Housing and Shift Mechanism ] Transmission Component Overviews.

- Transmission on vehicles with a stop/start system: install the transmission neutral position sensor - arrow - and tighten the bolt, see - item 11 - in => [ Transmission Housing and Shift Mechanism ] Transmission Component Overviews to specification.

- Install both flange shafts with springs, thrust washers and tapered rings. Refer to => [ Transmission Component Overviews ] Transmission Component Overviews.

5th Gear, Installing

• Make sure the bracket (30-211A) and the support bridge (T10323) are installed.

- Secure the bolt on the bracket (30-211A) with the nut - A -.

Installed Position, 5th Gear

The groove all the way around - arrow - faces the transmission housing.

- Install the 5th gear.

Checking 5th Gear Synchronizer Ring

- Before reinstalling the gear and synchronizer ring for 5th gear, press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.

- Install the 5th gear with needle bearing.

- Place the 5th gear synchronizer ring onto the gear.

- If disassembled, assemble the 5th gear synchronizing hub with operating sleeve. Refer to => [ Assembling the 5th Gear Locking Collar/Synchronizer
Hub ] Input Shaft.

Installed Position of 5th Gear Synchronizer Hub/Locking Collar

The pointed teeth on the locking collar - arrow 1 - and the high collar on the synchronizer hub - arrow 2 - face the transmission housing.

The notches - arrow 3 - on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring (lower).

5th Gear Synchronizer Ring with Cast Locking Pieces

- Cover all openings with a cloth to prevent foreign objects from getting into the transmission.

- Install the 5th gear synchronizing hub with operating sleeve.

• Make sure there is enough clearance when installing the synchronizing hub.

- Loosen the input shaft support.

Wear safety gloves.

- Clean the synchronizing hub and 5th gear threaded holes of locking compound residue with a thread tap.

Otherwise, there is the danger that the bolts could shear off.

- Install the synchronizing hub and 5th gear bolts.

Installed Position of the Concave Washers for the 5th Gear Synchronizing Hub and Gear Bolts

The outer diameter - arrows - faces 5th gear.

- Tighten the bolts for the synchronizing hub and 5th gear to specification. Refer to => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.

- Engage 5th gear - arrow 1 - and 1st gear - arrows 2 and 3 - and then tighten the bolts - A - for the synchronizing hub with operating sleeve and the 5th gear to specification. See - item 4 - in => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.

- The input and output shafts are blocked after engaging both gears, the synchronizing hub and the toothed gear cannot turn. Both bolts can be tightened now.

- Install the 5th gear selector fork.

Adjusting 5th Gear

- Engage 5th gear. Loosen the bolt - 1 -. Press the locking collar and selector fork in the direction of the arrow, then tighten the bolt - 1 - to 25 Nm.

• Check measurement: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.

- Remove 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.

- Move the shift lever (selector lever) through all the gears.

- Install the transmission housing cover. Refer to => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.

- Install the guide sleeve for the release bearing. Refer to => [ Clutch Release Mechanism ] Service and Repair.

- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism ] Service and Repair.

- Fill the transmission fluid, refer to one of the following:

• Rabbit, MY 2006-2009, refer to => [ Pay attention to the
following list for the subject - ] Transmission.

• Golf, from MY 2010, refer to => [ Pay attention to the
following list for the subject - ] Transmission.