Transmission Housing
Transmission Housing
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244B)
• Transmission Support (VW 353)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Tube 37 mm Dia. (VW 416 B)
• Guide Pin (VW 436 A)
• Guide Pin (VW 439)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Guide Pin (10-15)
• Thrust Pad (3124)
• Bearing Driver (3264)
• Subframe Support Assem. Device (3290)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Drift (T10168)
• Thrust Piece (T10203)
• Drift (T10169) or (T10362)
• Kukko Extractor 14.5-18.5 mm (Kukko 21/2)
• Kukko Extractor (Kukko 21/4)
• Kukko Support (Kukko 22/2)
• Thread Adapter from Kukko Support (Kukko 22/1)
1 Transmission Housing
• When replacing: adjust the output shaft and differential, refer to => [ Adjustment Overview ] Adjustment Overview.
• Changes to the grooved ball bearing/input shaft mount area, see - item 3 -=> [ Transmission Housing ] Input Shaft Overview.
2 Sealing Cap
3 Oil Drain Plug
• Tightening specification, refer to => [ Different Versions of
the Oil Fill and Oil Drain Plugs ] Service and Repair.
4 Oil Seal
• If installed, always replace.
5 Oil Filler Plug
• Tightening specification, refer to => [ Different Versions of
the Oil Fill and Oil Drain Plugs ] Service and Repair.
6 Locking Pin
• For adjustment of the shift mechanism. Refer to => [ Shift Mechanism, Adjusting ] Adjustments.
• Can be replaced with non-disassembled transmission.
7 Bushing
• For the selector rods.
8 Lock Sleeve
9 Needle Bearing
• For the reverse shaft.
• Replace after each disassembly.
10 Outer Race/Tapered Roller Bearing
• For output shaft for 5th/6th and reverse gear.
• Removing and installing, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• 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 Adjustment Shim
• For output shaft for 5th/6th and reverse gear.
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
12 Outer Race/Tapered Roller Bearing
• For output shaft for 1st to 4th gear.
• Removing and installing, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• Adjust, if output shaft for 1st to 4th gear is replaced. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
13 Adjustment Shim
• For output shaft for 1st to 4th gear.
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
14 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing, refer to => [ Differential ] Differential.
• When replacing: adjust the differential, refer to => [ Adjustment Overview ] Adjustment Overview.
15 Adjustment Shim
• For the differential.
• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.
16 Bushing
• For selector shaft.
17 Sealing Plug
18 Oil Seal
• Removing and installing, refer to => [ Left Flange Shaft Seal ] Left Flange Shaft Seal.
Removing Cap - A -
- Punch a hole through the center of the rubber cap using a screwdriver - B - and pry out the cap in the - direction of the arrow -.
Drive in Cap until Seated
Removing Locking Pin for Selector Shaft
- Break off bracket in released position.
- Guide a screwdriver - A - into the hole for the locking pin - B -.
- Pry out the locking pin in the - direction of arrow -.
Installed Position of Locking Pin
- Mark on the locking pin - arrow - must point to the slave cylinder connection - 1 -.
Dimension must be approximately 45° - a -.
Drive Locking Pin - arrow - for Selector Shaft in up to Tool Stop
• Locking pin must be released for driving in procedure.
Pulling out Bearing Bushing for Selector Rod
A Internal puller 14.5 to 18.5 mm, for example (21/2)
B Support, for example, (22/2)
Driving in Bushing for Selector Rod to Tool Stop
Pressing Lock Sleeve - A - out of Transmission Housing
- Arrange the transmission housing on the (VW 401) and (VW 402) so that the alignment bushings in the transmission housing are not damaged.
Driving Out Lock Sleeve for Non-Disassembled Transmission using Guide Pin (10-15)
• Locking bolt and selector shaft removed.
- Rotate transmission so that lock sleeve does not fall into transmission.
Lock Sleeve Differentiation
The following lock sleeves may be installed:
Lock sleeve with a shoulder - arrow 1 -
Lock sleeve without a shoulder - arrow 2 -
Drive In Lock Sleeve with Shoulder as far as Stop on Tool
• Transmission housing fastened to clutch housing.
Drive In Lock Sleeve without Shoulder as far as Stop on Tool
• Transmission housing fastened to clutch housing.
Pulling Needle Bearing for Reverse Shaft out of Transmission Housing
A Internal puller 23.5 to 30 mm, for example, (21/4)
B Support, for example, (22/2)
• Needle bearing is destroyed when it is removed and must be replaced.
Pressing Needle Bearing - A - into Transmission Housing
- During pressing sequence, place thrust washer - B - for reverse shaft on needle bearing.
- Support transmission housing directly beneath bearing mount using (VW 416 B).
Pulling Out Bushing for Selector Shaft
- Use the thread adapter from the support (22/1) - arrow -.
- Hold spindle of (3290) firmly in place and tighten nut - B -.
A Internal puller 14.5 to 18.5 mm, for example, (21/2)
Driving Bearing Bushing - A - for Selector Shaft in to Tool Stop
Driving Out Sealing Plugs - 1 -
- Drive the sealing plug - 1 - from the inner side of the transmission housing toward the outside - arrow -.
Driving in Sealing Plugs - 1 -
- Using the (3264), drive in the sealing plugs to dimension - a - approximately 3 mm below upper edge of housing.