Transmission Cover and 5th Gear
Transmission Cover and 5th Gear
• If only 5th gear 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, 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) , or equivalent
• 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 ] Clutch Release Mechanism Overview.
• Be careful not to damage 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) , mount the following 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 the driving sleeve (32-111) only at a later time.
Under the Output Shaft Bracket:
• Support bridge (T10323)
• Thrust pad (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 the 5th Gear
- Cover the openings in the transmission housing with a cloth.
- Move the selector fork - 1 - into neutral.
- Remove the bolt - 2 - with the shift jaw for 5th gear.
- Remove both bolts - arrows - for the selector for bases.
- 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 - 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 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 half shell (T10309/1) between the 5th gear - A - and the mount for 5th gear selector fork - B -.
• The half shell (T10309/1) must be placed under the synchronizer ring.
- Press the puller into the end position, if necessary.
- Rotate the half shell (T10309/1) to the opposite side in the - direction of the arrow -.
- Insert the threaded insert (T10309/3) into the half shell.
- Install the second half shell (T10309/1) and mount the tube (T10309/2) on the tool.
- Check the synchronizer hub after pulling for damage.
- Replace the 5th gear synchronizer ring
- Remove 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 drive gear, make sure the leg does not bend outward. Check the 5th gear for damage.
• Slightly heat the 5th gear with the inductive heat unit (V.A.G 1416) or equivalent, if necessary.
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 Cover and 5th Gear Overview ] Transmission Cover and 5th Gear Overview.
- Install the clutch release lever and release bearing. Refer to => [ Clutch Release Mechanism Overview ] Clutch Release Mechanism Overview.
- Fill the transmission fluid. Refer to => [ Pay attention to the following list for the subject -. ] Transmission, Installing.