Transmission, Disassembling: Notes

Fig 1: Identifying Transmission Secured To Assembly Stand With Bolts

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

NOTE:

If one of the fastening holes does not touch the Transmission Support, place washers between the fastening hole and the Transmission Support.

-- Turn the transmission the assembly stand with the oil drain plug facing down.

-- Place the Drip Tray underneath.

-- Drain the transmission fluid.

-- Remove the clutch slave cylinder with the release bearing -arrows-.

Fig 2: Identifying Slave Cylinder With Release Bearing

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-- Transmission on vehicles with Stop/Start system: remove the Transmission Neutral Position Sensor -G701- -arrow-.

Fig 3: Identifying The Transmission Neutral Position Sensor

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Make Sure During the Following Step That the Gearshift Shaft is Not Blocked by the Locking Elbow -arrow-.

Fig 4: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move the gearshift shaft into neutral.

-- Remove the Back-Up Lamp Switch -F4- -1-.

-- Remove the locking bolt -2-.

-- Then remove the bolts -3-.

-- Remove selector shaft with shift cover -4- from transmission housing.

NOTE:

Use the Pry Lever 80-200 to press against the spring force of the securing bushing direction of -arrow- so that the gearshift shaft -1- does not touch the securing bushing -2- when removing.

Fig 5: Securing Bushing

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-- Remove the left and right flange shaft bolts. To do this, install two bolts into the flange and counterhold the flange shaft using a pry bar.

Fig 6: Identifying Flange Shaft, Installation

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-- Remove the flange shafts and the pressure spring.

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

Fig 7: Identifying Interior Clutch Housing Bolts

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NOTE:

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

-- Lock the input shaft as follows:

Fig 8: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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The Stub Shaft Splines on the Input Shaft have Different Lengths on the Transmission.

-- Either place the Press Piece - Multiple Use VW455 over the input shaft on the clutch housing.

-- Or place the Press Piece - Front Wishbone 3160 over the input shaft on the clutch housing.

Fig 9: Identifying Separating Tool And Sleeve 3160

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-- Tension the Separating Tool - 5-60 mm -A-, for example Puller - Kukko Quick Action Separating Tool - 5-60 mm 17/0, tightly behind the splines on the input shaft.

The back of the Separating Tool - 5-60 mm must touch the Press Piece - Multiple Use VW455 or the Press Piece - Front Wishbone 3160 free-of-play.

NOTE:

Metal and plastic covers are installed for the input shaft.

The locking ring -A- has been discontinued together with the plastic cover for the input shaft.

Fig 10: Identifying Input Shaft Sealing Cap Types

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-I- = Steel cover for the input shaft with locking ring -A-
-II- = Plastic cover for the input shaft without locking ring