Transmission, without a Sealing Cap Circlip
Transmission, without a Sealing Cap Circlip
=> [ Disassembly ]
=> [ Assembly ]
- Transmission housing without a sealing cap circlip - A -.
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 (21/1)
• Kukko Separating Tool 5-60 mm (17/0)
• Kukko Support (Kukko 22/1)
• Bracket (30-211 A)
• Thrust Piece (T10042)
• Drift (T10169) or (T10362) , see => [ Locking Sleeve Differentiation ] Transmission Housing.
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Hot Air Blower (V.A.G 1416)
• Drip Tray for VAS 6100 (VAS 6208)
Disassembly
- Attach the transmission to the assembly stand with bolts - arrows -.
• If one of the bolt holes does not touch the transmission support place shims between the hole and the transmission support.
- Turn the transmission in the assembly stand so that the drain plug is facing down.
- Place the drip tray underneath.
- Drain the transmission fluid.
- Remove the slave cylinder with release bearing bolts - arrows - and the slave cylinder with release bearing.
Make sure the gear shift shaft is not blocked by the locking pin - arrow -.
- Move the gear shift shaft into neutral.
- Remove the backup lamp switch (F4) - 1 -.
- Remove the locking screw - 2 -.
- Then, remove the bolts - 3 -.
- Remove the gear shift shaft with shift cover - 4 - from the transmission housing.
- Remove the left and right flange shaft bolts. To do this, install two bolts into the flange and counter hold the flange shaft using a pry bar.
- Remove the flange shafts and pressure springs.
- Remove the bolts - B - that connect the clutch housing to the transmission housing.
• One bolt - arrow - is located outside of the bolting flange.
- Secure the input shaft as follows:
The stub shaft splines on the input shaft has different lengths on the transmission.
- Either place the thrust tube (VW 455) over the input shaft on the clutch housing.
- Or place the sleeve (3160) over the input shaft on the clutch housing.
- Tension the separating tool - A -, for example, kukko separating tool 5-60 mm (17/0) , tightly behind the splines on the input shaft.
The back of the separating tool must touch the thrust tube (VW 455) or the sleeve (3160) free of play.
- Pierce the rubber piece cover - C - in the center with a screwdriver.
- Remove the cover from the transmission housing.
A Support, for example, kukko support (22/1)
B Internal puller 8-12 mm, for example, kukko puller 12-14.5 mm (Kukko 21/1)
Remove the locking ring - C - from the grooved ball bearing on the input shaft/transmission housing as follows:
- Hold one end of the locking ring secure using the screwdriver - A -.
- Pry the other end out of the groove in the grooved ball bearing in the - direction of the arrow -using the screwdriver - B -.
- Pry out the rest of the locking ring using the screwdriver - B -.
- Remove the washer - 1 - from the transmission housing - 2 -, if equipped.
• If the transmission is being replaced, see if the washer must be installed.
- Remove the bolts - A - that attach the transmission housing to the clutch housing.
- Install the adapter (VW 771/40) into the threaded hole in the transmission housing.
- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, (V.A.G 1416).
- Remove the transmission housing from the clutch housing in the - direction of the arrow - using the slide hammer (VW 771/1).
• If necessary, carefully pry up all around and alternating between sides on the protruding flange. Be careful not to damage the sealing surfaces.
- Remove the washer - 1 - from the grooved ball bearing - 2 -, if equipped.
- If the transmission is being replaced, see if the washer must be reinstalled.
- Remove the separating tool - A - and the thrust tube (VW 455) (illustration) or the sleeve (3160) from the input shaft.
A second technician is needed to help remove the output shafts from the clutch housing.
- Lift the differential - 1 - with the left hand. With the right hand, left the output shaft for 1st to 4th gear together with the selector shafts - 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 shaft out of the clutch housing - arrow B -
• If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.
- Removing the input shaft seal.
• Always replace the grooved ball bearing => [ (Item 6) Grooved Ball Bearing ] Input Shaft on the input shaft.
Assembly
• Press the new grooved ball bearing => [ (Item 6) Grooved Ball Bearing ] Input Shaft onto the input shaft.
- Install the input shaft - 1 -, the output shaft for 5th/6th gears - 2 - together with the selector shaft with selector forks - 3 -, selector fork - 4 - and reverse shaft - 5 -.
- Then, install the differential - 1 -.
• A 2nd technician is needed to help install the shafts into the clutch housing.
- Hold the output shaft for 1st through 4th gear - 3 - and the selector shafts with selector forks - 4 - with the right hand.
- Lift the differential - 1 - slightly with the left hand.
- Have the second technician lift the input shaft, the 5th/6th gear output shaft and reverse gear - 2 - together with the reverse shaft slightly at the same time.
- Install the 1st to 4th gear output shaft in the - direction of the arrow -.
• Places on the input shaft, output shafts and final drive gear/differential must engage.
- Together with a second technician, now place the shafts and differential in their bearing seats.
- Install the bracket (30-211 A) for the input shaft to the clutch housing.
• The clutch housing is shown in the illustration rotated 180°.
- Install the bolt - A - just far enough until the input shaft starts to lift.
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.
Measure the shoulder above the grooved ball bearing mount.
The area under 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 -.
On 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.
- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see the next graphic).
- Heat the transmission housing in the area around the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, (V.A.G 1416).
• 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 install the transmission housing.
- Heat the transmission housing using the 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 new bolts - A, B and C - to specification.
If the steel bolts (outer hex head) are the replacement part, pay attention to the allocation:
A Bolt with a permanent washer
B Bolt without a washer
C Bolt with a 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 grooved ball bearing/input shaft locking ring - 1 -.
- Remove the bracket (30-211 A) for the input shaft.
- Install the selector shaft lock sleeve all the way onto the tool. Refer to => [ Locking Sleeve Differentiation ] Transmission Housing.
- Turn the transmission with opening for the shift shaft in the assembly stand upward.
- Install the gear shift shaft - 1 - into the lower bearing - 2 - and into the selector forks - 3 -.
• The cover => [ (Item 2) Cover ] Transmission Housing is not shown in the illustration.
- Push the gear shift shaft - 1 - against the retaining sleeve - 2 - in the - direction of the arrow - and guide is through the selector fork all the way down using the shift finger - 3 -.
• The gear shift cover - 4 - must be parallel to the bolting surface on the transmission housing.
• It must be possible to move the gear shift shaft easily (forward and backward).
• If the gear shift cover is at an angle to the bolting surface, then the gear shift shaft is not installed into the lower bearing.
- Tighten the bolts - 3 - on the gear shift shaft 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 -.
- Install the left and right flange shafts, the pressure springs, the thrust washers and the tapered rings.
- Install the input shaft seal.
- Install the slave cylinder with release bearing and tighten the bolts - arrows - to specification, see => [ (Item 4) Bolt ] Clutch Release Mechanism Overview.
- Move the gear shift lever (selector lever) through all the gears.
- Drive the cap into the transmission housing to the stop using the thrust piece (T10042)
