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Transmission Housing

Special tools and workshop equipment required 

Fig 1: Exploded View Of Transmission Housing Components As Of Transmission Manufacture Date 190503
GWWN34-10038Courtesy of VOLKSWAGEN UNITED STATES, INC.
  1. Transmission Housing
    • When replacing: adjust the output shaft and differential, refer to ADJUSTMENT OVERVIEW .
    • Changes to the grooved ball bearing/input shaft mount area, see "Transmission Housing" under: INPUT SHAFT OVERVIEW .
    • Changes to the cover/input shaft mount area, see item  4.
  2. Cover
    • Removing, refer to Fig 2.
    • Installing, refer to Fig 3.
  3. Oil Drain Plug
    • Tightening specification, refer to Figure.
  4. Seal
    • Always replace, if equipped.
  5. Oil Fill Plug
    • Tightening specification, refer to Figure.
  6. Locking Pin
    • For adjusting the shift mechanism, refer to SHIFT MECHANISM, ADJUSTING .
    • Can be replaced with the transmission not disassembled.
    • Removing, refer to Fig 4.
    • Installed position, refer to Fig 5.
    • Installing, refer to Fig 6.
  7. Bushing
    • For the selector shaft with selector forks.
    • Removing, refer to Fig 7.
    • Installing, refer to Fig 8.
  8. Retaining Sleeve
    • Removing, when the transmission is disassembled. Refer to Fig 9.
    • Removing, when the transmission is not disassembled. Refer to Fig 10.
    • Different retaining sleeves, refer to Fig 11.
    • Installing a retaining sleeve with a shoulder, refer to Fig 12.
    • Installing the retaining sleeve without a shoulder, refer to Fig 13.
  9. Needle Sleeve
    • For the reverse shaft.
    • Replace after removing.
    • Removing, refer to Fig 14.
    • Installing, refer to Fig 15.
  10. Outer Race/Tapered Roller Bearing
  11. Adjusting Shim
    • Output shaft, 5th, 6th and reverse gears.
    • Adjustment overview, refer to ADJUSTMENT OVERVIEW .
  12. Outer Race/Tapered Roller Bearing
  13. Adjusting Shim
  14. Outer Race/Tapered Roller Bearing
  15. Adjusting Shim
  16. Bushing
    • For the gear shift unit shaft.
    • Removing, refer to Fig 16.
    • Installing, refer to Fig 17.
  17. Plug
  18. Seal

Removing the Cover 

Fig 2: Knocking Rubber Through At Center Of Sealing Cap Using Screwdriver
GWWN34-10039Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Pierce the rubber cover -A- in the center with a screwdriver -B- and pry it out in the -direction of the arrow-.

Installing the Cover 

Fig 3: Drive In Cap Until Stop
GWWN34-10040Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Locking Pin for the Gear Shift shaft 

Fig 4: Removing Lock Elbow For Selector Shaft
GWWN34-10042Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the locking pin in its unlocked position.

-- Guide a screwdriver -A- into hole of the locking pin -B-.

-- Pry out the locking pin in the -direction of the arrow-.

Locking Pin, Installed Position 

Fig 5: Installation Position Of Lock Elbow
GWWN34-10043Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- The mark on the locking pin -arrow- must point toward the connection on the clutch slave cylinder -1-.

Dimension -a- must be approximately 45°.

Installing the Locking Pin for the Gear Shift Shaft 

Fig 6: Drive Lock Bracket For Selector Shaft In Up To Tool Stop
GWWN34-10044Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:

The locking pin -arrow- must be unlocked when being installed.

Removing the Selector Shaft Bushing 

Fig 7: Pulling Out Bearing Bushing For Selector Rod
GWWN34-1576Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm 21/2

B - Counter-support, for example, Kukko support 22/2

Installing the Selector Shaft Bushing, to the Tool Stop 

Fig 8: Driving In Bearing Bushing For Shift Rod To Tool Stop
GWWN34-10309Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fig 9: Press Lock Sleeve Off With Transmission Removed
GWWN34-10046Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Retaining Sleeve -A- from the Transmission Housing 

-- Position the transmission housing on the thrust plates VW 401 and VW 402 so that the alignment sleeves inside the transmission housing do not get damaged.

Removing the Retaining Sleeve from a Assembled Transmission using the Guide Piece -10-15- 

Fig 10: Driving Out Lock Sleeve For Non-Disassembled Transmission Using Guide Pin 10 - 15
GWWN34-10047Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Turn the transmission so that the retaining sleeve cannot fall into the transmission.

Lock Sleeve Differentiation 

Fig 11: Lock Sleeve Differentiation
GWWN34-10855Courtesy of VOLKSWAGEN UNITED STATES, INC.

The following locking sleeves may be installed:

Locking sleeve with a shoulder -arrow 1-, refer to Fig 12.

Locking sleeve without a shoulder -arrow 2-, refer to Fig 13.

Driving in the Lock Sleeve with a Shoulder, to the Tool Stop 

Fig 12: Drive In Lock Sleeve With Shoulder As Far As Stop On Tool
GWWN34-10308Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving in the Lock Sleeve without a Shoulder, to the Tool Stop 

Fig 13: Drive In Lock Sleeve Without Shoulder As Far As Stop On Tool
GWWN34-10861Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Reverse Shaft Needle Sleeve from the Transmission Housing 

Fig 14: Pulling Needle Bearing For Reverse Shaft Out Of Transmission Housing
GWWN34-1578Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Internal puller 23.5 to 30 mm , for example, Kukko extractor 23.5-30 mm 21/4

B - Counter-support, for example, Kukko support 22/2

NOTE:

The needle sleeve will get damaged when it removed and must be replaced.

Installing the Needle Sleeve into the Transmission Housing 

Fig 15: Pressing Needle Bearing - A - Into Transmission Housing
GWWN34-1010Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- While installing, place the thrust washer -B- for the reverse shaft onto the needle sleeve.

-- Support the transmission housing beneath the bearing mount using the tube 37 mm dia. VW 416 B.

Removing the Selector Shaft Bushing 

Fig 16: Removing the Selector Shaft Bushing
GWWN34-10970Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Use the thread adapter from the Kukko support 22/1 -arrow-.

-- Hold the spindle on the subframe support assem. device 3290 and turn the nut -B-.

A - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm 21/2

Installing the Gear Shift Shaft Bushing -A-, to the Tool Stop 

Fig 17: Driving Bearing Bushing For Selector Shaft In To Tool Stop
GWWN34-10310Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Plug 

Fig 18: Driving Out Sealing Plugs
GWWN34-10050Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Drive the plug -1- from the inner side of the transmission housing toward the outside -arrow-.

Installing the Plug 

Fig 19: Driving In Sealing Plugs
GWWN34-10051Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Using the bearing driver 3264, drive in the plug -1- to dimension -a- approximately 3 mm below the upper edge of the housing.

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