Transmission Housing
Transmission Housing
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Transmission Support (VW 353)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Tube 37 mm Dia. (VW 416 B)
• Guide Piece (VW 436 A)
• Guide Pin (VW 439)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Guide Piece (10-15)
• Thrust Pad (3124)
• Bearing Driver (3264)
• Subframe Support Assem. Device (3290)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Drift (T10169) or (T10362)
• Drift (T10168)
• Thrust Piece (T10203)
• Kukko Extractor 14.5-18.6 mm (21/2)
• Kukko Extractor 23.5-30 mm (21/4)
• Kukko Support (22/2)
• Threaded Adapter from Kukko Support (22/1)
1 Transmission Housing
• When replacing: Adjust the output shafts and differential, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).
• Changes to the grooved ball bearing/input shaft mount area, see => [ (Item 3) Transmission Housing ] Input Shaft Overview.
• Changes to the cover/input shaft mount area, see => [ (Item 4) Sealing Cap ] Transmission Component Overviews.
• Refer to the Parts Catalog.
2 Cover
• Removing, refer to => [ Removing the Cover ].
• Installing, refer to => [ Installing the Cover ].
3 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill and Drain Plugs: ] Service and Repair.
4 Seal
• Always replace, if equipped.
5 Transmission Fluid Fill Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill and Drain Plugs: ] Service and Repair.
6 Locking Pin
• For adjusting the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
• Can be replaced with the transmission assembled.
• Removing, refer to => [ Removing the Locking Pin for the Gear Shift shaft ].
• Installed position, refer to => [ Locking Pin, Installed Position ].
• Installing, refer to => [ Installing the Locking Pin for the Gear Shift Shaft ].
7 Bushing
• For the selector shafts with selector forks.
• Removing, refer to => [ Removing the Selector Shaft Bushing ].
• Installing, refer to => [ Installing the Selector Shaft Bushing, to the Tool Stop ].
8 Retaining Sleeve
• Removing when the transmission is disassembled, refer to => [ Removing the Retaining Sleeve from the Transmission Housing ].
• Removing when the transmission is assembled, refer to => [ Removing the Retaining Sleeve from a Assembled Transmission using the ].
• Different retaining sleeves, refer to => [ Lock Sleeve Differentiation ].
• Installing a retaining sleeve with a shoulder, refer to => [ Driving in the Lock Sleeve with a Shoulder, to the Tool Stop ].
• Installing the retaining sleeve without a shoulder, refer to => [ Driving in the Lock Sleeve without a Shoulder, to the Tool Stop ].
9 Needle Sleeve
• For the reverse shaft.
• Always replace if removed.
• Removing, refer to => [ Removing the Reverse Shaft Needle Sleeve from the Transmission Housing ].
• Installing; refer to => [ Installing the Needle Sleeve into the Transmission Housing ].
10 Outer Race/Tapered Roller Bearing
• Output shaft, 5th, 6th and reverse gears.
• Removing and installing, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• When replacing: adjust the output shaft for 5th and 6th and reverse gear. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
11 Adjusting Shim
• Output shaft, 5th, 6th and reverse gears.
• Adjustment overview, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).
12 Outer Race/Tapered Roller Bearing
• Output shaft, 1st to 4th gears.
• Removing and installing, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• When replacing: adjust the output shaft for 1st to 4th gear. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
13 Adjusting Shim
• Output shaft, 1st to 4th gears.
• Adjustment overview, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).
14 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing, refer to => [ Differential ] Service and Repair.
• When replacing: adjust the differential, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).
15 Adjusting Shim
• For the differential.
• Adjustment overview, refer to => [ Adjustment Overview ] Final Drive, Differential (02Q Manual Transmission).
16 Bushing
• For the gear shift shaft.
• Removing, refer to => [ Removing the Selector Shaft Bushing ].
• Installing, refer to => [ Installing the Gear Shift Shaft Bushing , to the Tool Stop ].
17 Plugs
• Removing, refer to => [ Removing the Plug ].
• Installing, refer to => [ Installing the Plug ].
18 Seal
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
Removing the Cover
- Pierce the cover - A - with a screwdriver - B - and pry it out of the cover in the - direction of the arrow -.
Installing the Cover
Removing the Locking Pin for the Gear Shift shaft
- Remove the locking pin in its unlocked position.
- Guide a screwdriver - A - into hole of the locking pin - B -.
- Pry out the locking pin in the - direction of the arrow -.
Locking Pin, Installed Position
- The mark on the locking pin - arrow - must point toward the connection on the clutch slave cylinder - 1 -.
Dimension - a - must be approximately 45°.
Installing the Locking Pin for the Gear Shift Shaft
• The locking pin - arrow - must be unlocked when being installed.
Removing the Selector Shaft Bushing
A Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm (21/2)
B Counter support, for example, Kukko support (22/2)
Installing the Selector Shaft Bushing, to the Tool Stop
Removing the Retaining Sleeve - A - from the Transmission Housing
- Position the transmission housing on the thrust plates (VW 401) and (VW 402) so that the alignment sleeves inside the transmission housing do not get damaged.
Removing the Retaining Sleeve from a Assembled Transmission using the Guide Piece (10-15)
• Locking pin and selector shaft removed.
- Turn the transmission so that the lock sleeve cannot fall into the transmission.
Lock Sleeve Differentiation
The following lock sleeves may be installed:
Lock sleeve with a shoulder - arrow 1 -, refer to => [ Driving in the Lock Sleeve with a Shoulder, to the Tool Stop ].
Lock sleeve without a shoulder - arrow 2 -, refer to => [ Driving in the Lock Sleeve without a Shoulder, to the Tool Stop ].
Refer to the Parts Catalog.
Driving in the Lock Sleeve with a Shoulder, to the Tool Stop
• The transmission housing is bolted to the clutch housing.
Driving in the Lock Sleeve without a Shoulder, to the Tool Stop
• The transmission housing is bolted to the clutch housing.
Removing the Reverse Shaft Needle Sleeve from the Transmission Housing
A Internal puller 23.5 to 30 mm, for example, kukko extractor 23.5-30 mm (21/4)
B Counter-support , for example, Kukko support (22/2)
• The needle sleeve will get damaged when it is removed and must be replaced.
Installing the Needle Sleeve into the Transmission Housing
- While installing, place the thrust washer - B - for the reverse shaft onto the needle sleeve - A -.
- Support the transmission housing beneath the bearing mount using the tube 37 mm dia. (VW 416 B).
Removing the Selector Shaft Bushing
- Use the thread adapter from the Kukko support (22/1) - arrow -.
- Hold the spindle on the subframe support assm. device (3290) and turn the nut - B -.
A Internal puller, for example, Kukko extractor 14.5-18.5 mm (21/2)
Installing the Gear Shift Shaft Bushing - A -, to the Tool Stop
Removing the Plug
- Drive the sealing plug - 1 - from the inner side of the transmission housing toward the outside - arrow -.
Installing the Plug
- Using the bearing driver (3264) , drive in the sealing plug - 1 - approximately 3 mm - a - below the upper edge of the housing.