Transmission Housing Cover and 5th Gear
Transmission Housing Cover and 5th Gear
• If only the 5th gear has to be removed, follow this procedure:
• If the transmission housing must be removed, refer to => [ Transmission ] Transmission.
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)
• 2-Arm Puller (20/10)
• Bracket (30-211A)
• Driving Sleeve (32 -111)
• Thrust Piece (T10030/4)
• Tube 37 mm Dia. (VW 416 B)
• Puller (T10309)
• Two-Arm Puller (T10040)
• Puller Legs with Thrust Piece (T10040/2A + /3)
• Support Bridge (T10323)
• Wheel Bearing Assembly Set (3253/7)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Piece (40 -105)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
Removing
- Remove the clutch release lever and release bearing. 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 the 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)
• Input shaft may be supported by driving sleeve (32-111) only at a later time.
Under the Output Shaft Bracket:
• Support bridge (T10323)
• Subframe support assembling device (3253/7)
• Thrust piece con. 8/65 (VW 433)
- Secure the transmission to the transmission support (VW 353).
- Remove the transmission housing cover - arrow -.
- Make sure the puller legs (T10040/2A) can be installed correctly under the 5th gear.
Removing the 5th Gear
- Cover the openings with a cloth.
- Move the shift fork - 1 - into neutral.
- Remove the bolt - 2 - for 5th gear with the shift segment.
- Remove both bolts - arrows - for the pivot pin.
- Remove the pivot pin.
- Remove the shift 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 remove the bolt - A - for the synchronizer hub and 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 the 5th gear synchronizer hub together with the locking collar and locking pieces.
Use puller (T10309).
- First, insert shell (T10309/1) between the 5th gear - A - and the 5th gear selector fork mount - B -.
• Shell (T10309/1) must be placed below the synchronizer ring.
- Puller must be pressed into end position, if necessary.
- Turn shell (T10309/1) on the opposite side in the - direction of the arrow -.
- Install the threaded insert (T10309/3) into the puller.
- Then install the second half shell (T10309/1) and place tube (T10309/2) onto tool.
- Check the synchronizer hub after pulling for damage.
- Replace the synchronizer ring.
- Remove the 5th gear synchronizing hub with operating sleeve.
- Remove the 5th gear. (shown here on a different transmission).
- Install the leg first - A -.
B thrust piece (40 - 105)
• When remove the gear, make sure the leg does not bend outward. Check the 5th gear for damage.
Installing
Install the 5th gear. Refer to => [ 5th Gear, Installing ] Transmission.
- Apply sealing paste (AMV 188 200 03) evenly over the sealing surface on the transmission housing cover.
- Install the transmission housing cover. Refer to => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism ] Service and Repair.
- Fill the transmission with fluid. Refer to => [ Pay attention to the
following list for the subject - ] Transmission.