Transmission Housing Cover and 5th Gear
Transmission Housing Cover and 5th Gear
• If only the 5th gear has to be removed, follow this procedure:
• Transmission fluid does not need to be drained for this procedure. When the transmission housing cover is removed, the transmission must sit with the cover side facing upward.
• If the transmission housing must be removed, follow the disassembly and assembly procedure. 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)
• (M 8 x 100 mm Bolt)
• 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)
• Subframe Support Assembling Device (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 Overview ] Service and Repair.
• Be careful not to damaged the bearing for the input and output shafts when removing and installing the 5th gear.
• When securing the transmission to the (VW 353), mount the following tools for support:
Under the Input Shaft:
• (30-211A)
• (32 - 111)
• (T10030/4)
• Input shaft may be supported by the (32 - 111) only at a later time.
Under the Output Shaft Bracket
• (T10323)
• (3253/7)
• (VW 433)
- Secure the transmission on the (VW 353).
- Remove the transmission housing cover - arrow -.
- Make sure the (T10040/2A) can be installed correctly under the 5th gear.
Removing just the 5th Gear
- Cover the openings in the transmission housing with a cloth.
- Move the shift fork - 1 - into neutral.
- Remove the bolt - 2 - with the shift jaw for the 5th gear.
- Remove both bolts - arrows - for the pivot pin.
- Remove the pivot pin.
- Remove the 5th gear shift fork.
- It is not necessary to remove the spring - 3 - and the locking collar - 4 -.
- Engage 5th gear - arrow1 - and 1st gear - arrows2 - and - 3 - and remove the bolts - A - for the synchronizer hub and the 5th gear.
- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the 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 locking collar and locking pieces. Use the (T10309) for this.
- Insert the (T10309/1) between the 5th gear - A - and the mount for the 5th gear shift fork - B -.
• The (T10309/1) must be placed under the synchronizer ring.
- Press the puller into the end position, if necessary.
- Rotate the (T10309/1) to the opposite side in the - direction of the arrow -.
- Insert the (T10309/3) into the (T10309/1)
- Install the second (T10309/1) and mount the (T10309/2) on the tool.
- Check the synchronizer hub after pulling for damage.
- Replace the 5th gear synchronizer ring
- Remove the 5th gear selector gear with needle bearing.
- Remove the 5th gear drive gear. The illustration shows it on a different transmission.
- Insert the hook - A -.
B (40 - 105) or M10 x 20 bolt, 17 mm
• When remove the drive gear, make sure the hook does not bend outward. Check the 5th gear for damage.
• Warm the gear with the (V.A.G 1416).
Installing
Install the 5th gear. Refer to => [ 5th Gear, Installing ] Transmission.
- Install the transmission housing cover and tighten the bolts to specification. Refer to => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Fill the transmission with fluid. Refer to => [ Pay attention to the
following list for the subject - ] Installing.