Transmission Housing Cover and 5th Gear
Transmission Housing Cover and 5th Gear
• If only the 5th has to be removed, follow this procedure:
• The 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 transmission 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)
• Inductive Heat Unit (V.A.G 1416)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Bracket (30-211 A)
• Driving Sleeve (32-111)
• Thrust Piece (T10030/4) from Assembly Tool (T10030)
• 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)
• 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 transmission support (VW 353) , install the following special tools for support:
Under the Input Shaft:
• Bracket (30 - 211 A)
• Driving Sleeve (32-111)
• Thrust Piece (T10030/4)
• The 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 pad 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 Just 5th Gear:
- Cover the openings in the transmission housing with a cloth.
- Move the selector fork - 1 - into neutral.
- Remove the bolt - 2 - for the 5th gear selector fork shift jaw.
- Remove both selector fork base bolts - arrows -.
- Remove the selector for bases.
- Remove the 5th gear selector 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 - remove the bolts - A - for the synchronizer hub and the 5th gear.
- The input and output shafts are blocked after both gears are engaged. The synchronizer hub and the gear cannot turn. Both bolts can be loosened now.
• Remove any locking fluid 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 the puller (T10309) for this.
- Insert the shell (T10309/1) between the 5th gear - A - and the mount for the 5th gear selector fork - B -.
• The shell (T10309/1) must be placed under the synchronizer ring.
- Press the puller into the end position, if necessary.
- Rotate the shell (T10309/1) to the opposite side in the - direction of the arrow -.
- Insert the threaded insert (T10309/3) into the shell.
- Install the second shell (T10309/1) and place the tube (T10309/2) on the tool.
- Check 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.
- Insert the puller leg - A -.
B Thrust piece (T10040/3) or a 17 mm M10 x 20 bolt
• When remove the gear, make sure the puller leg does not bend outward. Check the 5th gear for damage.
• Heat the gear with the inductive heat unit (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 Cover and 5th Gear ] Transmission Components Overview.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism Overview ] Service and Repair.
- Fill the transmission fluid. Refer to => [ Pay attention to the following list for the subject - ] Transmission, Installing.