Transmission, without a Sealing Cap Circlip
Transmission, without a Sealing Cap Circlip
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 => [ Retaining 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 transmission support 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 support so that the drain plug is facing down.
- Place the drip tray underneath.
- Drain the fluid from the transmission.
- Remove the right flange shaft (the illustration shows the left flange shaft). To do this, install two bolts into the flange and counter hold the flange using a pry bar.
- Remove the slave cylinder with the release bearing bolts - arrows - and slave cylinder.
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 - 1 -.
- Remove the locking screw - 2 -.
- Then, remove the bolts - 3 -.
- Remove the gear shift unit - 4 - from transmission housing.
- Remove the left flange shaft bolt. To do this, install two bolts into the flange and counter hold the flange using a pry bar.
- Remove the left flange shaft and the pressure spring.
- Remove the bolts - B - that secure 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 (W 455) or the sleeve (3160) free of play.
- Pierce the rubber cover - C - in the center, with a screwdriver.
- Remove the cover from the transmission housing.
A Counter support, for example, Kukko puller (22/1)
B Internal puller 8 to 12 mm, for example, Kukko puller 12-14.5 mm (21/1)
• You can push through the center of the cover when removing the cover - 1 -
• Pry the cover - 2 - carefully out of the transmission housing.
Remove the lock ring - C - from the grooved ball bearing on the input shaft/transmission housing as follows:
- Hold one end of the lock ring secure using a screwdriver - A -.
- Pry the other end out of the groove in the grooved ball bearing in the - direction of the arrow - using a screwdriver - B -.
- Pry out the rest of the lock ring using the screwdriver - B -.
- Remove the washer - 1 - from the transmission housing - 2 -, if equipped.
• If the transmission is replaced, see if the washer must be installed.
- Remove the bolts - A - that secure the transmission housing to the clutch housing.
- Install adapter for VW 771 slide hammer (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, hot air blower (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 alternate 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 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 shafts from the clutch housing.
- Lift the differential - 1 - with the left hand. With the right hand, lift 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 and 6th gear - 3 - together with the selector shafts out of the clutch housing - arrow B -.
• If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.
- Remove the input shaft seal.
• Always replace the grooved ball bearing (- item 6 - in the => [ Input Shaft Overview ] Input Shaft Overview) on the input shaft.
Assembly
• Press the new grooved ball bearing (- item 6 - in the => [ Input Shaft Overview ] Input Shaft Overview) onto the input shaft.
- Install the input shaft - 1 -, the 5th/6th gear and reverse gear output shaft - 2 - the selector shaft with selector fork - 3 -, the selector fork - 4 - and the reverse gear 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 - 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 and reverse gear output shaft - 2 - together with the reverse gear shaft slightly at the same time.
- Install the 1st to 4th gear output shaft in the - direction of arrow -.
• Parts of the input shaft, output shafts and final drive gear/differential must engage.
- Together with the second technician, now place the shafts and differential in their bearing seats.
- Secure the bracket (30-211 A) to the input shaft and 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.
On 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 - in the => [ Input Shaft Overview ] Input Shaft Overview).
Measure the Shoulder Above the Grooved Ball Bearing Mount
The Area under the Grooved Ball Bearing Seat - arrow - in the Transmission Housing has been Changed
- 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, hot air blower (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 a hot air gun, for example hot air blower (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 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 lock 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 => [ Retaining sleeve differentiation ] Transmission Housing.
- Turn the transmission with the opening for the selector 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 - in the => [ Transmission Housing ] 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 unit - 4 - must stand 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 - for the gear shift unit - 4 -.
- Install the locking screw - 2 -, the locking pin - arrow - must not be installed when doing so.
- Install the backup lamp switch - 1 -.
- Install the input shaft seal.
- Install the slave cylinder with release bearing and bolts - arrows - and tighten them to specification, see - item 4 - in the => [ Clutch Release Mechanism Overview ] Description and Operation.
- Move the shift lever through all the gears.
- Drive the cap into transmission housing until seated using the thrust piece (T10042)
- Install the left flange shaft and pressure spring, the thrust washer and the tapered ring.
- Install the right flange shaft and pressure spring, the thrust washer and the tapered ring.