Transmission
Transmission
Special tools, testers and auxiliary items required
• Holding Fixture (VW 313)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Thrust Disc (VW 412)
• Transmission Support (3221)
• Guide Bolt (T10079)
• Punch (VW 407)
• Tube 31.5 mm Dia (VW 418 A)
• Pressure Washer (3074)
• Thrust Piece (T10080)
• Thrust Block (T10083)
• Drip Tray (V.A.G 1306)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• 2-Arm Puller (20/10)
• Kukko Puller 65-160 mm (18/1)
• Kukko Separating Tool 12-75 mm (17/1)
• M8 x 15 Bolt
• Sealing Paste (AMV 188 200 03)
Disassembly
- First change the (3221).
- Drill a 11 mm diameter hole - arrow -.
- Attach the transmission to the (3221) - arrows -.
- Place the drip tray for example, (V.A.G 1306), underneath.
- Drain the transmission fluid.
- Remove the clutch release lever - A - with the release bearing and guide sleeve bolts - arrows -.
- Remove the right flange shaft bolt - B -.
- Install 2 bolts into the flange shaft flange and counter hold the flange shaft with a pry bar.
- Remove the flange shaft with spring, thrust washer and tapered ring.
- Remove the transmission housing cover - arrow - bolts and cover.
- Remove the pin - 1 - for the 5th gear shift fork - 2 - and remove the shift fork.
- Remove the 5th gear synchronizer hub lock ring - 3 -.
- Remove the lock ring - 4 - from the 5th gear wheel.
- Remove the input and output shaft bearing mount bolts - A -.
- Remove the 5th gear synchronizer hub and drive gear.
- Remove the shift mechanism bolt - B - (secures reverse gear).
- Remove the bolt for the flange shaft and remove the flange shaft, by installing two bolts into the flange and counter holding flange shaft using a pry bar.
- Remove the flange shaft - C - with spring.
- Turn the transmission in the mounting bracket and the clutch housing upward.
- Remove the bolts that secure the transmission housing from inside clutch housing.
- Carefully pry off the clutch housing all around while alternating sides on the protruding flange, do not damage sealing surfaces.
• Do not tilt the clutch housing.
• The roller bearing and the bearing seat on the input and output shafts must not be damaged.
- Remove the differential - A - from the transmission housing.
- Remove the shift unit and cover - A -. Move the shift shaft into neutral. Remove the bolts - arrows - and pull the shift shaft out of the transmission housing.
- Remove the pins - B - from the top of the transmission.
- Remove the backup lamp switch (F4) - C -.
- Remove the bolt - A - for the reverse gear axle.
- Remove the pins - B - on the bottom side of the transmission.
• Do not remove the sealing cap - arrow - to remove transmission.
- Remove the input and output shafts together with the bearing mount, shift forks and reverse gear.
• Position the transmission housing so as not to damage the alignment bushings.
• When removing the components, have a 2nd technician there to keep them from falling down.
- Remove the input and output shafts from the bearing mount with grooved ball bearing. Refer to => [ Removing the Bearing
Mount and Grooved Ball Bearing ] Input Shaft.
Assembling
• Install the bearing mount with grooved ball bearing onto the input and output shafts. Refer to => [ Installing the Bearing
Mount with Grooved Ball Bearing ] Input Shaft.
• Install the 5th gear drive gear needle bearing sleeve onto the input shaft. Refer to => [ Installing the 5th
Gear Needle Bearing Sleeve. ] Input Shaft.
- Place the assembled input shaft - 2 -, output shaft - 1 -with bearing mount/grooved ball bearing in (T10085).
- Install the shift forks - 4 - into the shaft locking collars.
- Install the reverse gear axle - 3 - with reverse gear.
- Attach the (T10079) to the threaded pins (secures reverse gear) - arrow -.
- Install the components into the transmission housing. Guide the (T10079) through the hole for securing the shift mechanism in the transmission housing.
- Remove the (T10079).
- Make sure the shift forks are engaged correctly inside the locking collars before installing the bearing mount.
- Carefully pressing the bearing mount in together with input and output shaft as far as the stop.
- Install the reverse gear axle bolt - A -.
- Install the pins - B - in the bottom of the transmission.
- Install the backup lamp switch (F4) - C -.
- Install the pins - B - on the top of the transmission.
- Move the shift rail into the neutral position.
- Apply sealing paste (AMV 188 200 03) evenly on the sealing surface of the shift cover.
- Install the shift unit with cover - A -. Tighten the bolts - arrows -.
- Attach the input and output shaft bearing mount with new bolts - A -.
• Tighten to specification diagonally and in stages starting at the center.
- Tighten shift forks nut - B -.
- Install the differential - A -.
- Apply sealing paste (AMV 188 200 03) to the sealing surface.
- Tighten the clutch housing to the transmission housing.
- Turn the transmission in the mounting bracket with transmission housing upward.
- Position the 5th gear - 1 -.
Installed Position of the 5th Gear:
High inner collar - arrow - faces toward transmission housing cover.
- Install the 5th gear with needle bearing.
- Place the 5th gear synchronizer ring onto the selector gear.
- Position the 5th gear synchronizer cover together with the locking collar and stop ring.
- Insert the 5th gear shift fork - 2 - and slide in the mounting pins - 1 - as far as the stop in the - direction of the arrow -.
- Select a new lock ring - arrow -.
- Determine thickest lock ring that can still be inserted for the input shaft - 3 - and output shaft - 4 - and install it.
For the correct lock rings refer to the Parts Catalog.
- Install the transmission housing cover.
- Install both flange shafts, pressure springs, thrust washers and the tapered rings.
- Install the clutch release lever together with release bearing and guide sleeve. Refer to the => [ Clutch Release Lever with Release Bearing and Guide Sleeve ] Service and Repair.