Transmission, With Cap/Input Shaft Circlip
Transmission, with Cap/Input Shaft Circlip
With cap/input shaft circlip - A -
=> [ Disassembly ]
=> [ Assembly ]
Special tools, testers and auxiliary items required
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Tube (VW 455) or Sleeve (3160)
• Slide Hammer-Complete Set (VW 771)
• Kukko Puller 12-14.5 mm (Kukko 21/1)
• Kukko Separating Tool 5-60 mm (Kukko 17/0)
• Kukko Support (Kukko 22/1)
• Extractor Lever (VW 681)
• Bracket (30-211A)
• Thrust Piece (T10042)
• Thrust Piece (T10143)
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Heat Gun (V.A.G 1416)
• Drift (T10169)
• or Drift (T10362) => [ Lock Sleeve Differentiation ] Transmission Housing
Disassembly
- Secure the transmission to (VW 353) with bolts - arrows -.
• If one of the fastening holes does not contact the (VW 353), place shims between the hole and the (VW 353).
- Rotate the transmission in the assembly stand with the oil drain plug downward.
- Place a drip tray underneath.
- Drain the transmission fluid from the transmission.
- Remove the right flange shaft (the illustration shows the left flange shaft).
- Remove the slave cylinder with release bearing bolts - arrows - and slave cylinder/release bearing.
- Remove the clutch housing to transmission housing bolts - B - from inside the clutch housing.
• One clutch housing bolt - arrow - is located outside of the bolting flange.
- Secure the input shaft.
The stub shaft splines on the input shaft has different lengths on the transmission.
- Either place the (VW 455) over the input shaft on the clutch housing.
- Or place the (3160) over the input shaft on the clutch housing.
- Tension the separating device - A -, for example, (17/0) tightly behind the input shaft splines.
While doing this, the back side of the separating device must contact the (VW 455) or the (3160) free of play.
- Remove the left flange shaft.
- On vehicles with the stop/start system: remove the transmission neutral position sensor (G701) - arrow -.
In the following step, ensure selector shaft is not locked by the locking pin - arrow -.
- Move the shift shaft to the neutral position.
- Remove the locking screw - 2 -.
- Remove bolts - 3 -.
- Remove the backup lamp switch (F4) - 1 -.
- Pull the selector shaft - 4 - out of the transmission housing.
- Remove the cap/input shaft circlip - A -.
- Punch a hole through the center of the rubber cap - C - using a screwdriver.
- Remove the cap from the transmission housing.
A Support, for example, (22/1)
B Internal puller 8 to 12 mm, for example, (21/01)
Remove the circlip - C - from the grooved ball bearing of the input shaft/transmission housing as follows:
- Hold one end of the circlip in place using a screwdriver - A -.
- Using the screwdriver - B -, pry other end out of groove for grooved ball bearing in the - direction of the arrow -.
- By repositioning the screwdriver - B -, pry the circlip out further.
- Remove the transmission housing to clutch housing bolts - A -.
- Install the VW 771/40 into the threaded hole of the transmission housing.
- Heat the transmission housing using a heat gun, for example, (V.A.G 1416) in the area of the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.
- Remove the transmission housing from the clutch housing using the VW 771/1 in the - direction of the arrow -.
• If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.
- Remove the separating device - A - and the VW 455 (illustration) or the (3160) from the input shaft.
A 2nd technician is required to remove the shafts from the clutch housing.
- Lift the differential - 1 - with the left hand. With the right hand, lift the output shaft for 1st to 4th gears together with the selector rods - 2 - - arrow A -.
- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear - 3 - together with the selector rods out of the clutch housing - arrow B -.
• If necessary, the differential can be shifted again in clutch housing after lifting the shafts.
- Pry out the input shaft seal using the (VW 681).
• The grooved ball bearing - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview on input shaft must always be replaced.
Assembly
• A new grooved ball bearing - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview must be pressed onto the input shaft.
- First insert the input shaft - 1 -, output shaft for 5th/6th gears - 2 - together with the selector rod - 3 -, reverse gear shift fork - 4 - and reverse shaft - 5 -.
Pay attention to the different bearing for the reverse gear shift fork.
The reverse gear shift fork - 1 - is mounted on the axle - 2 - behind the 5th and 6th gear shift rod - 3 -.
The reverse gear shift fork - 1 - is mounted on the shift rod with the 5th and 6th gear shift fork - 2 -.
Continuation for All
- Then insert the differential - 1 -.
• A 2nd technician is required for further installation of the shafts into the clutch housing.
- As shown in the illustration, grasp the output shaft for 1st to 4th gears - 3 - with the selector rods - 4 - in the right hand.
- Lift the differential slightly with the left hand.
- At the same time, the 2nd technician slightly lifts the input shaft, output shaft for 5th/6th gears and reverse gear - 2 - together with the reverse shaft.
- Insert the output shaft for 1st to 4th gears in the - direction of the arrow -.
• Input shaft, output shafts and final drive gear/differential must engage.
- Together with the 2nd technician, displace the shafts and differential in their bearing seats.
- Install the (30-211A) for the input shaft to the clutch housing.
• For the sake of illustration, the clutch housing is shown rotated 180°.
- Install the bolt - A - far enough until the input shaft rises slightly.
The grooved ball bearing/input shaft only fits in one position in the transmission housing.
There is a flattened area on the grooved ball bearing and the bearing mount.
• If the flattened areas - A and B - are present, do not insert any washers above and below the grooved ball bearing. Refer to => [ Grooved Ball Bearing Changes ] Input Shaft.
• The flattened sides - A - on the grooved ball bearing and on the bearing mount - B - must align in the transmission housing.
- Mark the flattened side with color.
- Place a mark on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (=> next illustration).
- Heat the transmission housing using a heat gun, for example, (V.A.G 1416) in the area of the bearing seat for the grooved ball bearing/input shaft to 100 °C (212 °F) for approximately 10 minutes.
• It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.
• Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.
• Align the mark on the grooved ball bearing - A - with the mark on the transmission housing - B - and mount the transmission housing.
- Install the transmission housing and tighten the bolts - A, B and C - to specification.
For steel bolts (hex head) as replacement part, note the allocation:
A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer
- Install the circlip - 1 - for the grooved ball bearing/input shaft.
- Remove the input shaft (30 - 211 A).
- If the selector shaft lock sleeve has been removed, drive it in now as far as the stop on tool. Refer to => [ Lock Sleeve Differentiation ] Transmission Housing.
- Turn the transmission with the opening for the selector shaft in the assembly stand upward.
- Insert the selector shaft - 1 - into the lower mounting - 2 - and into the shift forks - 3 -.
• To improve clarity, the cap is removed.
- Press the selector shaft - 1 - against the lock sleeve - 2 - in the - direction of the arrow - and guide downward with the shift finger - 3 - through the shift forks until seated.
• Shift cover - 4 - must be parallel to bolting surface on transmission housing during this.
• Selector shaft must be able to be moved easily in the selector motion (up and down).
• If the shift cover is at an angle to the bolting surface, the selector shaft is not inserted in the lower bearing.
- Tighten the bolts - 3 - for the shift cover - 4 -.
- Install the locking screw - 2 -, the locking pin - arrow - must not be installed when doing so.
- Install the backup lamp switch (F4) - 1 -.
- On vehicles with the stop/start system: install the transmission neutral position sensor (G701) - arrow - and tighten the bolt - item 10 - => [ Bolt ] Transmission Component Overview to the specification.
- Drive the input shaft seal in until seated.
- Install the slave cylinder with release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder With Release Bearing.
- Shift through all gears.
- Drive the cap into the transmission housing until seated.
- Secure the cap with the circlip - A -.
- Install the flange shafts with the springs, thrust washers and tapered rings.