Transmission, Without A Sealing Cap CIRCLIP: Disassembly

-- Install the transmission to the assembly stand with the bolts -arrows-.

NOTE:

If one of the holes does not align with the transmission support place shims between the hole and the transmission support.

Fig 1: Securing Transmission To Assembly Stand With Bolts

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-- Turn the transmission in the assembly stand so that the drain plug is facing down.

-- Place a drip tray underneath.

-- Drain the gear oil from the transmission.

Fig 2: Installing Flange Shaft

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-- Remove the right flange shaft (the illustration shows the left flange shaft)

-- Remove the slave cylinder with the release bearing bolts -arrows- and release bearing.

Fig 3: Identifying Slave Cylinder With Release Bearing

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-- Remove the clutch housing to the transmission housing bolts -B-.

Fig 4: Identifying Interior Clutch Housing Bolts

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NOTE:

One bolt -arrow- is located outside of the bolting flange.

-- Secure the input shaft.

The stub shaft splines on the input shaft has different lengths on the transmission.

Fig 5: Removing Separating Tool And Thrust Tube From Input Shaft

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-- Either place the thrust tube VW 455 over the input shaft on the clutch housing.

-- Or place the sleeve 3160 over the input shaft on the clutch housing.

Fig 6: Placing Sleeve 3160 Over Input Shaft On Clutch Housing

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-- Tension the separating tool -A-, for example Kukko separating tool 5-60 mm 17/0, tightly behind the splines on the input shaft.

The back of the separating tool must touch the thrust tube VW 455 or the sleeve 3160 free of play.

-- Remove the left flange shaft.

Fig 7: Installing Flange Shaft

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Make sure the gear shift shaft is not locked by the locking pin -arrow-.

Fig 8: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move the gear shift shaft into neutral.

-- Remove the locking screw -2-.

-- Then, remove the bolts -3-.

-- Remove the backup lamp switch -F4- -1-.

-- Remove the gear shift unit -4- from the transmission housing.

-- Pierce the rubber cover -C- in the center using a screwdriver.

Fig 9: Identifying Support, Internal Puller & Cap

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-- Remove the cap from the transmission housing.

A - Counter support, for example, Kukko support 22/1

B - Internal puller 8 to 12 mm, for example, Kukko puller 12-14.5 mm 21/1

Remove the locking ring -C- from the grooved ball bearing on the input shaft/transmission housing as follows:

Fig 10: Removing Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing Using Screwdrivers & VW 309

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-- Hold one end of the locking ring secure using a screwdriver -A-.

-- Pry the other end out of the groove in the grooved ball bearing in the -direction of arrow- using a screwdriver -B-.

-- Pry out the rest of the locking ring using the screwdriver -B-.

-- Remove the washer -1- from the transmission housing -2-, if equipped.

Fig 11: Identifying Laying Washer Above Grooved Ball Bearing

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If the transmission is replaced, check whether the washer must be installed again.

-- Remove the transmission housing to the clutch housing bolts -A-.

Fig 12: Identifying Transmission Housing To Clutch Housing Bolts

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-- Install the adapter VW 771/40 into the threaded hole in the transmission housing.

Fig 13: Installing Adapter VW 771/40 Into Threaded Hole Of Transmission Housing

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-- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100°C (212°F) for 10 minutes using a heat gun, for example, V.A.G 1416.

-- Remove the transmission housing from the clutch housing in the -direction of arrow- using the slide hammer VW 771/1.

NOTE:

If necessary, carefully pry up all around and alternating between sides on protruding flange. Be careful not to damage the sealing surfaces.

-- Remove the washer -1- from the grooved ball bearing -2-, if equipped.

Fig 14: Placing Washer On Grooved Ball Bearing

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-- If the transmission is replaced, see if it is necessary to install the washer again.

-- Remove the separating tool -A- and the thrust tube VW 455 (illustration) or the sleeve 3160 from the input shaft.

Fig 15: Removing Separating Tool And Thrust Tube From Input Shaft

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A second technician is needed to help remove the shafts from the clutch housing.

-- Lift the differential -1- with the left hand. With the right hand, left the output shaft for 1st to 4th gears together with the selector shaft with selector forks -2- -arrow A-.

Fig 16: Lifting Differential & Output Shaft With Selector Rods

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-- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear -3- together with the selector shaft with selector forks out of the clutch housing -arrow B-

NOTE:

If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.

-- Pry out the input shaft seal using the extractor lever VW 681.

NOTE:

Always replace the grooved ball bearing INPUT SHAFT OVERVIEW on the input shaft.