Transmission Housing
Transmission Housing
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Transmission Support (VW 353)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Tube 37 mm Dia. (VW 416 B)
• Guide Piece (VW 436 A)
• Guide Pin (VW 439)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Guide Piece (10-15)
• Thrust Pad (3124)
• Bearing Driver (3264)
• Subframe Support Assem. Device (3290)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Drift (T10168)
• Drift (T10169) or (T10362) , see=> [ Retaining sleeve differentiation ]
• Thrust Piece (T10203)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Extractor 23.5-30 mm (21/4)
• Kukko Support (22/2)
• Thread Adapter from Kukko Support (22/1)
1 Transmission Housing
• When replacing: Adjust the output shafts and differential. Refer to => [ Adjustment Overview ] Adjustment Overview.
• Changes to the grooved ball bearing/input shaft mount area. See - item 3 - in the => [ Input Shaft Overview ] Input Shaft Overview.
• Changes to the cover/input shaft mount area. See - item 4 - in the => [ Transmission Housing and Gear Shift Unit Overview ] Transmission Housing and Gear Shift Unit Overview.
• Refer to the Parts Catalog.
2 Cover
• Removing, refer to => [ Removing the cover ].
• Installing, refer to => [ Installing the cover ].
3 Drain Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill and Drain Plugs ] Service and Repair.
4 Seal
• Always replace, if equipped.
5 Transmission Fluid fill Plug
• Tightening specification, refer to => [ Different Versions of the Oil Fill and Drain Plugs ] Service and Repair.
6 Locking Pin
• For adjusting the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
• Can be replaced with transmission assembled.
• Removing, refer to => [ Removing the locking pin for the gear shift shaft ].
• Installed position, refer to => [ Installed position: locking pin ].
• Installing, refer to => [ Driving the locking pin for the selector shaft in up to the tool stop ].
7 Bushing
• For the selector shafts.
• Removing, refer to => [ Removing the selector shaft bushing ].
• Installing, refer to => [ Installing the selector shaft bushing all the way in to the tool stop ].
8 Retaining Sleeve
• Removing when the transmission is disassembled. Refer to => [ Removing the retaining sleeve from the transmission housing ].
• Removing when the transmission is assembled. Refer to => [ Removing the retaining sleeve on a assembled transmission using the ].
• Different retaining sleeves. Refer to=> [ Retaining sleeve differentiation ].
• Installing a retaining sleeve with a shoulder, refer to => [ Drive in the retaining sleeve with shoulder as far as the stop on the tool ].
• Installing a retaining sleeve without a shoulder, refer to => [ Drive in the retaining sleeve without a shoulder as far as the stop on the tool ].
9 Needle Sleeve
• For the reverse gear shaft.
• Always replace if removed.
• Removing, refer to => [ Removing the reverse shaft needle sleeve from the transmission housing ].
• Installing, refer to => [ Installing the needle sleeve into the transmission housing ].
10 Outer Race/Tapered Roller Bearing
• For the 5th, 6th and reverse gear output shaft.
• Removing and installing, refer to => [ 5th, 6th and Reverse Gears Output Shaft Overview ] 5th, 6th and Reverse Gears Output Shaft Overview.
• When replacing: adjust the output shaft for 5th/6th and reverse gear. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
11 Adjusting Shim
• For the 5th, 6th and reverse gear output shaft.
• Overview, refer to => [ Adjustment Overview ] Adjustment Overview.
12 Outer Race/Tapered Roller Bearing
• For the 1st to 4th gear output shaft.
• Removing and installing, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• When replacing: adjust the output shaft for 1st to 4th gear. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
13 Adjusting Shim
• For the 1st to 4th gear output shaft.
• Overview, refer to => [ Adjustment Overview ] Adjustment Overview.
14 Outer Race/Tapered Roller Bearing
• For the differential
• Removing and installing, refer to => [ Differential ] Service and Repair.
• When replacing: adjusting the differential, refer to => [ Differential, Adjusting ] Differential, Adjusting.
15 Adjusting Shim
• For the differential
• Overview, refer to => [ Adjustment Overview ] Adjustment Overview.
16 Bushing
• For the selector shaft.
• Removing, refer to => [ Removing the selector shaft bushing ].
• Installing, refer to => [ Installing the gear shift shaft bushing all the way to the tool stop ].
17 Plug
• Removing, refer to => [ Removing the plug ].
• Installing, refer to => [ Installing the plug ].
18 Shaft Seal
• For the left flange shaft.
• Removing and installing, refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
Removing the cover
- Pierce the rubber cover - A - in the center using a screwdriver - B - and pry it out in the - direction of the arrow -.
Installing the cover
Removing the locking pin for the gear shift shaft
- Remove the pin in its unlocked position.
- Insert a screwdriver - A - into the hole for the locking pin - B -.
- Pry out the locking pin in the - direction of the arrow -.
Installed position: locking pin
• The mark on the locking pin - arrow - must point toward the connection on the clutch slave cylinder - 1 -.
• Dimension - a - must be approximately 45°.
Driving the locking pin for the selector shaft in up to the tool stop
• The locking pin - arrow - must be unlocked when being installed.
Removing the selector shaft bushing
A Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm (21/2)
B Counter support, for example, Kukko support (22/2)
Installing the selector shaft bushing all the way in to the tool stop
Removing the retaining sleeve from the transmission housing
- Position the transmission housing on the thrust plates (VW 401) and (VW 402) so that the retaining sleeves - A - inside the transmission housing do not get damaged.
Removing the retaining sleeve on a assembled transmission using the guide piece (10-15)
• Locking pin and selector shaft are removed.
- Turn the transmission so that the retaining sleeve cannot fall into the transmission.
Retaining sleeve differentiation
The following retaining sleeves may be installed:
Retaining sleeve with a shoulder - arrow 1 -. Refer to => [ Drive in the retaining sleeve with shoulder as far as the stop on the tool ].
Retaining sleeve without a shoulder - arrow 2 -. Refer to => [ Drive in the retaining sleeve without a shoulder as far as the stop on the tool ].
Refer to the Parts Catalog.
Drive in the retaining sleeve with shoulder as far as the stop on the tool
• The transmission housing is bolted to the clutch housing.
Drive in the retaining sleeve without a shoulder as far as the stop on the tool
• The transmission housing is bolted to the clutch housing.
Removing the reverse shaft needle sleeve from the transmission housing
A Internal puller 23.5 to 30 mm, for example, Kukko extractor 23.5-30 mm (21/4)
B Counter support, for example, Kukko support (22/2)
• The needle sleeve will get damaged when it is removed and must be replaced.
Installing the needle sleeve into the transmission housing
- While installing, place the thrust washer - B - for the reverse shaft onto the needle sleeve - A -.
- Support the transmission housing beneath the bearing mount the using Tube 37 mm dia. (VW 416 B).
Removing the selector shaft bushing
- Use the thread adapter from the Kukko support (22/1) - arrow -.
- Hold the spindle from the subframe support assem. device (3290) and turn the nut - B -.
A Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm (21/2)
Installing the gear shift shaft bushing - A - all the way to the tool stop
Removing the plug
- Remove the plug - 1 - from the inside of the transmission housing to the outside.
Installing the plug
- Install the plug approximately 3 mm under the upper edge of the housing - a - using the bearing driver (3264).