Continuation for All

Fig 1: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Hold one end of the locking ring secure with the Screwdriver -A-.

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

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

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

Fig 2: Identifying Transmission Housing To Clutch Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install Adapter VW771/40 into the threaded hole in the transmission housing.

Fig 3: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 approximately 10 minutes using a Hot Air Blower VAG1416, for example.

-- Remove the transmission housing from the clutch housing in direction of -arrow- using Slide Hammer VW771/1.

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 Separating Tool -A- and the Press Piece - Multiple Use VW455 or the Press Piece - Front Wishbone 3160 from the input shaft.

Fig 4: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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, lift the output shaft for 1st to 4th gear together with the gearshift rods -2- -arrow A-.

Fig 5: Identifying Differential & Output Shaft Lifted With Selector Rods

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-- At the same time, the second technician lifts the input-, reverse- and output shafts for 5th/6th gear and reverse gear -3- together with the gearshift rod out of the clutch housing -arrow B-.

NOTE:

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

-- Remove the input shaft seal.

NOTE:

Always replace the grooved ball bearing on the input shaft, refer to OVERVIEW - INPUT SHAFT .