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Transaxle Disassembly

NOTE: Prior to disassembling transaxle, measure and record pinion depth and ring gear back lash.
  1. Mount transaxle in Holding Fixture (VW 353) and drain fluid. Remove clutch release push rod from center of mainshaft and withdraw from bell housing end. Install Support Bar (30-211) across mouth of bell housing and install Thrust Pad (VW295a) between support bar and mainshaft. Tighten bolt of bar to take up clearance between bar and mainshaft. See Fig 1.
    Fig 1: Installation of Mainshaft Support Fixture
    G95J55789Courtesy of VOLKSWAGEN UNITED STATES, INC.
    Fig 2: Sectional View of Transaxle Assembly
    G95C55790Courtesy of VOLKSWAGEN UNITED STATES, INC.
  2. Remove rear housing bolts and rear housing. Remove back-up light switch, 5th gear lock out and selector shaft detent plunger. Remove selector shaft cover. Place gears in Neutral position and remove selector shaft and spring. Remove cap, snap ring and spring washer from drive shaft flange. Remove both drive shaft flanges with Remover (VW391).
  3. Lock transaxle in 5th and reverse gears and remove 5th gear synchronizer hub retaining bolt. Pry locking plate loose until tube can be turned and screw tube out of shift fork in a counter-clockwise rotation with Remover (3059).
    NOTE: DO NOT  pull selector rod out of tube.
  4. Remove 5th gear synchronizer, 5th gear and shift fork from transaxle case. Remove snap ring and thrust washer from 5th gear and pull 5th gear off pinion shaft with a puller.
    Fig 3: Removing 5th Gear Synchronizer Assembly
    G95D55791Courtesy of VOLKSWAGEN UNITED STATES, INC.
  5. Remove recessed bolts from mainshaft bearing retainer plate. Remove transaxle housing-to-transaxle housing bolts. Using Remover (3042), remove transaxle housing. Remove shift fork rod and forks. Remove 4th gear snap ring from pinion shaft. Remove mainshaft assembly and 4th gear on pinion shaft as an assembly.
  6. Remove snap ring from 3rd gear and remove 3rd gear, 2nd gear synchronizer, bearing and reverse gear. Use puller to remove 1st gear synchronizer and 1st gear. Remove pinion bearing retainer plate and pinion shaft. Remove differential assembly from case.
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