Transmission Housing

Special tools and workshop equipment required

Driving Sleeve VW 244 B
Transmission Support VW 353
Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 407
Tube 37 mm Dia.VW 416 B
Guide Piece VW 436 A
Guide Pin VW 439
Slide Hammer-Complete Set VW 771
Holding Fixture VW 801
Guide Piece 10-15
Thrust Pad 3124
Bearing Driver 3264
Subframe Support Assm. Device 3290
Torque Wrench (5-50 Nm) V.A.G 1331
Drift T10168
Drift T10169 or T10362
Thrust Piece T10203
Kukko Extractor 14.5-18.5 mm 21/2
Kukko Extractor 23.5-30 mm 21/4
Kukko Support 22/2
Threaded Adapter from Kukko Support 22/1

Fig 1: Identifying Screwdriver To Knock Through Rubber At Center Of Sealing Cap

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

Fig 2: Drive In Cap Until Stop

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Fig 3: Identifying Lock Elbow For Selector Shaft, Removal

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-- Break off the bracket in its unlocked position.

-- Insert a screwdriver -A- into the hole in the locking bracket -B-.

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

Fig 4: Identifying Installation Position Of Lock Elbow

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The mark on the locking pin -arrow- must point toward the connection on the clutch slave cylinder -1-.
Dimension -a- must be approximately 45°.

Fig 5: Drive Lock Bracket For Selector Shaft In Up To Tool Stop

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

Fig 6: Identifying Tool Assembly To Pull Out Bearing Bushing For Selector Rod

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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

Fig 7: Driving In Bearing Bushing For Shift Rod To Tool Stop

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Fig 8: Identifying Press Lock Sleeve Off With Transmission Removed

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-- Place the transmission housing on the thrust plates VW 401 and VW 402 without damaging the alignment sleeves in the transmission housing.

Fig 9: Driving Off Lock Sleeve With Non-Disassembled Transmission

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Locking pin and selector shaft removed.

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

Fig 10: Identifying Lock Sleeve Differentiation

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The following lock sleeves may be installed:

Lock sleeve with a shoulder -arrow 1-, refer to Fig 11.

Lock sleeve without a shoulder -arrow 2-, refer to Fig 12.

Allocate the components.

Fig 11: Drive In Lock Sleeve With Shoulder As Far As Stop On Tool

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The transmission housing is bolted to the clutch housing.

Fig 12: Drive In Lock Sleeve Without Shoulder As Far As Stop On Tool

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The transmission housing is bolted to the clutch housing.

Fig 13: Identifying Tool Assembly To Pull Out Needle Bearing For Reverse Shaft Of Transmission Housing

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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 be damaged when it is removed and must be replaced.

Fig 14: Driving In Needle Sleeve For Reverse Shaft Into Transmission Housing

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-- Lay the reverse shaft thrust washer -B- on the needle sleeve -A- while pressing it in.

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

Fig 15: Identifying Selector Shaft Bushing, Removal

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

-- Hold the spindle on the subframe support assm. device 3290 steady 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

Fig 16: Driving Bearing Bushing For Selector Shaft As Far As Tool Stop

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Fig 17: Driving Out Sealing Plugs

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-- Remove the plug -1- from the inside of the transmission housing to the outside.

Fig 18: Driving In Sealing Plug

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-- Install the plug -1- approximately 3 mm under the upper edge of the housing -a- using the bearing driver 3264.