Transmission, Without Cap/Input Shaft Circlip
Transmission, Without Cap/Input Shaft Circlip
- Without 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)
• Sleeve (30-21)
• Bracket (30-211A)
• Thrust Piece (T10042)
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Heat Gun (V.A.G 1416)
• Drift (T10169) or (T10362)
• Socket and Extended Bit (T10107)
Disassembly
- Secure the transmission to the assembly stand 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 oil drain plug downward.
- Place a drip tray underneath.
- Drain the transmission fluid oil from the transmission.
- Remove the right flange shaft or the stub shaft (the illustrations shows the left flange shaft)
As of transmission build date 4 November 2001, the right stub shaft was replaced by a flange shaft.
Continuation for All
- 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.
In the following step, ensure the selector shaft is not locked by the locking pin - arrow -.
- Move the shift shaft to the neutral position.
- Remove the locking screw - 2 -.
- Remove the bolts - 3 -.
- Remove the backup lamp switch (F4) - 1 -.
- Pull the selector shaft - 4 - off the transmission housing.
- Punch a hole through the center of the rubber cap - C - using a screwdriver.
- Remove the cap from transmission housing.
A Support, for example, (22/1)
B Internal puller 8-12 mm, for example, (21/01)
Remove the circlip - C - from the grooved ball bearing of the input shaft from the transmission housing as follows:
- Hold one end of the circlip in place using a screwdriver - A -.
- Using the screwdriver - B -, pry the other end out of the groove in the - direction of the arrow -.
- By repositioning the screwdriver - B -, pry the circlip out further.
- If present, remove the washer - 1 - from the transmission housing - 2 -.
• If the transmission is replaced, check whether a washer must be reinstalled.
- Remove the transmission housing to clutch housing bolts- A -.
- Install the VW 771/40 into the threaded hole in 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 the protruding flange taking care not to damage the sealing surfaces.
- If present, remove the washer - 1 - from the grooved ball bearing - 2 -.
- If the transmission is being replaced, check whether the washer must be reinstalled.
- 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 shafts 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 the 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 the 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.
- Insert the input shaft - 1 -, output shaft for 5th/6th gears - 2 - together with the selector rod - 3 -, shift fork - 4 - and reverse shaft - 5 -.
- 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.
- Now, 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, now 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 bolt - A - far enough until the input shaft rises slightly.
With some transmissions, there are flattened sides - A - on the input shaft grooved ball bearing and on the bearing mount - B -.
Check the input shaft grooved ball bearing and the transmission housing.
From transmission build date 10 April 2006 through approximately 21 January 2008
One washer each is inserted above and below the input shaft grooved ball bearing - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.
Measure the shoulder above the grooved ball bearing mount.
The area below the grooved ball bearing seat in the transmission housing has been changed - arrow -
- Place a washer (85 mm outer circumference) - 1 - on the grooved ball bearing - 2 -.
With some transmissions:
Flattened areas - A - on the input shaft grooved ball bearing and bearing mount - B -.
• Do not place any washers above and below the grooved ball bearing.
• 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 marking on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (=> next illustration).
- Heat transmission housing using a heat gun, for example, (V.A.G 1416) in area of bearing seat for 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.
• Align the mark on the grooved ball bearing - A - with the mark on the transmission housing - B - and mount the transmission housing.
- Heat the transmission housing using a heat gun, for example, (V.A.G 1416) in the grooved ball bearing/input shaft bearing set area to 100 °C (212 °F) for approximately 10 minutes.
- Apply sealing paste (AMV 188 200 03) evenly onto the sealing surface of the clutch housing.
- Install the transmission housing and tighten the bolts - A, B and C - to specification.
For steel bolts (hex head) as a replacement part, note the allocation:
A Bolt with permanent washer
B Bolt without washer
C Bolt with permanent washer
- If a washer was mounted on the grooved ball bearing before installation, then a washer - 1 - (outer diameter = 78.6 mm) must be installed after installation - 2 -.
- Install the circlip - 1 - for the grooved ball bearing/input shaft.
- Remove the (30 - 211 A) for the input shaft.
- If the selector shaft lock sleeve has been removed, drive it in now as far as the stop on the 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 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 the bolting surface on the transmission housing during this.
• Selector shaft must be able to be moved easily in 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 -.
- Drive the input shaft seal in flush.
- Install the slave cylinder with release bearing. Refer to => [ Slave Cylinder with Release Bearing ] Slave Cylinder With Release Bearing.
- Shift through all the gears.
- Drive the cap into the transmission housing until seated.
- Install the flange shaft and stub shaft with compression springs, thrust washers and tapered rings.
As of transmission build date 4 November 2001, the right stub shaft was replaced by a flange shaft.