Transmission Without A Sealing Cap CIRCLIP For Metal Cover: Notes

Fig 1: Identifying Transmission Housing Without Sealing Cap Circlip

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-A- : Circlip (NOT on the metal cover for the input shaft).

Special tools and workshop equipment required

Holding Plate VW309
Holding Fixture VW313
Transmission Support VW353
Thrust Tube VW455 or Sleeve 3160
Slide Hammer-Complete Set VW771
Kukko Puller 12-14.5 mm 21/1
Kukko Separating Tool 5-60 mm 17/0
Kukko Support Kukko 22/1
Bracket 30-211A
Thrust Piece T10042
Drift T10169 or T10362, refer to Figure.
Thrust Piece T40008
Torque Wrench (5-50 Nm) VAG 1331
Hot Air Blower VAG 1416
Drip Tray for VAS6100 VAS6208

Disassembly

-- Attach the transmission to the transmission support with bolts -arrows-.

Fig 2: Identifying Transmission Secured To Assembly Stand With Bolts

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NOTE:

If one of the bolt holes does not touch the transmission support place shims between the hole and the transmission support.

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

-- Place the drip tray underneath.

-- Drain the fluid from the transmission.

-- Remove the right flange shaft (the illustration shows the left flange shaft). To do this, install two bolts into the flange and counter hold the flange using a pry bar.

Fig 3: Identifying Flange Shaft, Installation

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

Fig 4: Identifying Slave Cylinder With Release Bearing

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

Fig 5: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move the gear shift shaft into neutral.

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

-- Remove the locking screw -2-.

-- Then, remove the bolts -3-.

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

NOTE:

Use the Pry Lever80-200 to press against the spring force of the securing bushing in the direction of -arrow- so that the gearshift shaft -1- does not touch the securing bushing -2- when removing.

Fig 6: Securing Bushing

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

Fig 7: Identifying Flange Shaft, Installation

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-- Remove the left flange shaft and the pressure spring.

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

Fig 8: Identifying Interior Clutch Housing Bolts

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NOTE:

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

-- Secure the input shaft as follows:

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

-- Either place the Thrust Tube VW455 over the input shaft on the clutch housing.

Fig 9: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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

Fig 10: Identifying Separating Tool -A- And Sleeve 3160

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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 VW455 or the Sleeve 3160 free of play.

-- Pierce the rubber cover -C- in the center, with a screwdriver.

Fig 11: Identifying Support, Internal Puller & Cap

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-- Remove the cover 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

NOTE:

You can push through the center of the cover when removing the cover -1-

Fig 12: Prying The Cover Out

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Pry the cover -2- carefully out of the transmission housing.

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

Fig 13: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

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

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

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

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

Fig 14: Identifying Laying Washer Above Grooved Ball Bearing

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If the transmission is replaced, see if the washer must be installed, refer to From transmission build date 10 April 2006 through approximately 21 January 2008 .

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

Fig 15: Identifying Transmission Housing To Clutch Housing Bolts

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

Fig 16: Identifying Adapter VW 771/40 Installed 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, Hot Air Blower VAG 1416.

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

NOTE:

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

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

Fig 17: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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-- If the transmission is replaced, see if the washer must be reinstalled, refer to From transmission build date 10 April 2006 through approximately 21 January 2008 .

-- Remove the separating tool -A- and the Thrust Tube VW455 (illustration) or the Sleeve 3160 from the input shaft.

Fig 18: Identifying Separating Tool And Thrust Tube Removed 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, lift the output shaft for 1st to 4th gear together with the selector shafts -2- -arrow A-.

Fig 19: Identifying Differential & Output Shaft Lifted With Selector Rods

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

NOTE:

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

-- Remove the input shaft seal.

NOTE:

Always replace the grooved ball bearing (-6-, refer to INPUT SHAFT ASSEMBLY OVERVIEW ) on the input shaft.

Assembly

Press the new grooved ball bearing (-6-, refer to INPUT SHAFT ASSEMBLY OVERVIEW ) onto the input shaft.

-- Install the input shaft -1-, the 5th/6th gear and reverse gear output shaft -2- the selector shaft with selector fork -3-, the selector fork -4- and the reverse gear shaft -5-.

Fig 20: Identifying Input Shaft And Output Shaft For 5th/6th Gears Inserted Together With Selector Rod, Shift Fork And Reverse Shaft

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-- Then install the differential -1-.

Fig 21: Identifying Differential, Input Shaft & Output Shaft

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NOTE:

A 2nd technician is needed to help install the shafts into the clutch housing.

-- Hold the output shaft for 1st through 4th gear -3- and the selector shafts -4- with the right hand.

-- Lift the differential -1- slightly with the left hand.

-- Have the second technician lift the input shaft, the 5th/6th gear and reverse gear output shaft -2- together with the reverse gear shaft slightly at the same time.

-- Install the 1st to 4th gear output shaft in the direction of -arrow-.

Parts of the input shaft, output shafts and final drive gear/differential must engage.

-- Together with the second technician, now place the shafts and differential in their bearing seats.

-- Secure the Bracket 30-211A to the input shaft and to the clutch housing.

Fig 22: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE:

The clutch housing is shown in the illustration rotated 180°.

-- Install the bolt -A- just far enough until the input shaft starts to lift.

On some transmissions, there are flattened sides -A- on the input shaft grooved ball bearing and on the bearing mount -B-.

Fig 23: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008

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Check the input shaft grooved ball bearing and the transmission housing.

Input shaft grooved ball bearing and transmission housing
No flattened sides on the grooved ball bearing -A- and bearing mount -B-, refer to From transmission build date 10 April 2006 through approximately 21 January 2008 .
Flattened sides on the grooved ball bearing -A- and bearing mount -B-, refer to Figure.