Disassembly And Assembly: Transmission: Notes

Special tools and workshop equipment required

Holding Plate VW 309
Transmission Support VW 353
Needle Bearing Drift VW 295
Driving Sleeve VW 244 B
Hot Air Blower V.A.G 1416
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 T10408
Plate T10408/3
Kukko Puller 65-160 mm 18/1
Support Bridge T10323
Subframe Support Assembling Device 3253/7
Thrust Piece VW 433
M7 x 35 Bolts with Washers
M 8 x 100 mm Bolt

Disassembly

-- Remove the clutch release lever with release bearing and the guide sleeve. Refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING .

Be careful not to damaged the bearing for the input and output shafts when removing and installing 5th gear.
When securing the transmission to the transmission support VW 353, install the following special tools for support:

Fig 1: Identifying 30-211A, VW 353 & T10323
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Under the Input Shaft:

Bracket 30-211 A
Driving sleeve 32-111
Thrust piece T10030/4

-- Secure the bolt on the bracket 30-211 A with the nut -A-.

Under the Output Shaft Bracket.

Support bridge T10323
Subframe support assembling device 3253/7
Thrust piece VW 433

-- Secure the transmission to the transmission support VW 353.

Fig 2: Identifying Transmission On Repair Stand

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-- Place the drip tray V.A.G 1306 underneath.

-- Remove the oil fill and drain plugs.

-- Drain the transmission fluid.

-- Remove the transmission housing cover -arrow-.

Fig 3: Identifying Transmission Housing Cover

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Remove the 5th gear selector fork as follows:

Fig 4: Identifying 5th Gear Shifter Fork

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-- Cover the openings with a cloth.

-- Move the selector fork -1- into neutral.

-- Remove the bolt -2- for 5th gear selector fork shift jaw.

-- Remove both selector for base bolts -arrows-.

-- Remove the selector fork bases.

-- Remove the 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 then remove the bolts -A- for the synchronizer hub and for the 5th gear.

Fig 5: Identifying Input Shaft And Output Shaft (Locked As Shown)

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-- The input and output shafts are blocked after engaging both gears, the synchronizer hub and the toothed gear cannot turn. Both bolts can now be loosened.

NOTE:

Remove any locking fluid residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.

-- Remove both bolts -arrows- for the reverse shaft support.

Fig 6: Identifying Reverse Shaft Support Bracket Bolts

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-- Remove the 3rd bolt -arrow- from the reverse shaft support.

Fig 7: Identifying 3rd Bolt For Reverse Gear Shaft Support

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-- Move the gear shift shaft into neutral and remove the gear shift unit. Remove the bolts -arrows- and pull the gear shift unit out of the transmission housing.

Fig 8: Identifying Selector Shaft Bolts

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-- Remove the sealing cap -A- and support pins -B- on the bottom of the transmission.

Fig 9: Identifying Sealing Cap And Pivot Pins On Underside Of Transmission

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-- Remove the support pins -A- on the top side of the transmission and transmission housing to clutch housing bolts -B- in the area of the differential.

Fig 10: Identifying Pivot Pins On Top Side Of Transmission And Bolts For Transmission Housing To Clutch Housing In Area Of Differential

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

Fig 11: Identifying Inside Clutch Housing Bolts & Output Shaft Bearing Support Nuts

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NOTE:

Do not remove the nuts -B- for the output shaft bearing support.

-- Remove both flange shafts.

Fig 12: Identifying Flange Shafts

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-- Remove the flange shafts with the springs, thrust washers and tapered rings.

Remove the following components together with the transmission housing:

Fig 13: Identifying T10408/3

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5th gear synchronizer hub
5th gear

Both plates T10408/3 must be attached to the 5th gear.
The plates must be located above the 2 ribs on the housing, opposite each other -arrows-.

NOTE:

There is a needle bearing under the 5th gear.

Secure the plates so that the needle bearing does not touch the 5th gear when removing the transmission housing.

Use the puller T10408 together with the following special tools:

Fig 14: Identifying Puller And Special Tools

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Thrust piece T10408/2
Plates T10408/3
Kukko puller 65-160 mm 18/1

-- Install the puller T10408 in the threaded holes in the transmission housing cover.

A - M7 x 35 bolts with washers

Tightening specification: 18 Nm

-- Place the pressure pieces T10408/2 on the shafts.

-- Install the Kukko puller 65-160 mm18/1 -A-.

Fig 15: Identifying Pressure Pieces T10408/2

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-- Remove the 5th gear synchronizer hub, the 5th gear and the transmission housing by tightening the spindles -A- - (approximately 1/2 turn).

-- Heat the 5th gear slightly using the inductive heat unit V.A.G 1416.

-- Remove the nuts -B- from the output shaft bearing support.

Fig 16: Identifying Inside Clutch Housing Bolts & Output Shaft Bearing Support Nuts

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-- Remove the selector forks -A- together with the rails.

Fig 17: Identifying Shift Forks & Reverse Gear Selector Mechanism

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-- Remove the reverse gear selector fork -B-.

-- Remove the reverse gear -A-, the input shaft -B- and the output shaft -C-, one after the other, from the clutch housing.

Fig 18: Identifying Reverse Gear, Input Shaft And Output Shaft From Clutch Housing In Sequence

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-- Remove the differential.

Assembly

-- Install the differential.

-- Always replace the seals -arrows- for the output shaft bearing support.

Fig 19: Identifying Output Shaft Bearing Support Sealing Rings

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NOTE:

The illustration only shows 3 of the 4 seals.

-- Insert the input shaft -1- and output shaft -2- together.

Fig 20: Identifying Output Shaft, Reverse Gear Drive Gear & Reverse Shaft

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-- Tighten the output shaft bearing support nuts to specification, see -item 11- in INPUT SHAFT, OUTPUT SHAFTS, DIFFERENTIAL AND SHIFT FORKS .

-- Install the reverse gear -3- on needle bearing in the clutch housing.

The shoulder -arrow- faces away from the clutch housing.

-- Make sure the reverse gear shaft -4- is complete, refer to REVERSE SHAFT ; do not mount the support on the reverse gear shaft.

-- Install the reverse gear shaft into the clutch housing.

-- Clean all threaded holes in the reverse gear shaft support of locking fluid; the cleaning can be done with a thread tap.

-- Mount the reverse gear shaft support.

-- Install the reverse gear selector fork -1- with the support for the reverse gear selector fork -2-, the spring -3- and the sliding piece -4-.

Fig 21: Identifying Reverse Gear Shift Fork Installed With Support For Reverse Gear Shift Fork, Spring And Sliding Piece

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Reverse gear location:

Fig 22: Identifying Reverse Gear Installation Position

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-- Install the reverse gear selector fork -A-.

Fig 23: Identifying Reverse Gear Selector Mechanism, Selector Forks & Gear Supports

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-- Install the selector forks -B- together with the rails.

The reverse gear shaft supports -C- are located in front of the rails.

-- Install the M8 x 100 mm stud bolts -A- into the reverse gear shaft support so that the shaft is aligned after fitting the transmission housing.

Fig 24: Identifying Studs -A- And Reverse Shaft Support

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-- Align the rails.

NOTE:

The shift segments must be installed in the grooves on the locking collars.

-- Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

-- Install the transmission housing.

Install the bolts for the reverse gear shaft support -arrow- as follows:

-- Install the bolt -a-.

-- Remove the stud bolts -A- (see the upper illustration).

-- Install the bolt -c-.

Fig 25: Identifying Bolts For Reverse Gear Shaft Support

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Tightening sequence:

-- Tighten the bolt -a- to 30 Nm.

-- Tighten the bolt -b - (see the lower illustration) to 25 Nm.

-- Tighten the bolt -c- to 25 Nm (see the previous illustration).

Fig 26: Identifying Bolt

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-- Install the support pin -arrow- for the selector forks. To do this align the shift mechanism using a screwdriver, so that the relevant support pin can be installed.

Fig 27: Identifying Selector Mechanism, Screwdriver And Pivot Pin

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-- Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the sealing cover.

-- Install the gear shift unit.

Install the gear shift unit as follows:

Fig 28: Identifying Selector Shaft With Selector Cover

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-- Move the gear shift rail into the neutral position.

-- Apply the sealing paste AMV 188 200 03 evenly onto the sealing surface of the cover.

-- Move the gear shift shaft into neutral.

-- Position the shaft so that selector finger -arrow- is inserted into the selector rails.

-- Tighten the shift unit cover bolts to the specification, see -item 17- in TRANSMISSION HOUSING AND GEAR SHIFT UNIT .

-- Install both flange shafts with springs, thrust washers and tapered rings. Refer to TRANSMISSION COMPONENT OVERVIEWS .

Fig 29: Identifying Both Flange Shafts With Springs, Thrust Washers And Tapered Rings

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