Transmission Housing, Servicing

Special tools and workshop equipment required

Bearing Driver - Multiple Use VW244B
Transmission Support VW353
Press Plate VW401
Press Plate VW402
Press Piece - Rod VW407
Press Piece - 37 mm VW416B
Guide Pin VW 436A
Press Piece - Guide Pin VW439
Slide Hammer Set VW771
Crankshaft Holding Fixture VW801
Guide Pins 10-15
Press Piece - Pivot Mount Bushing 3124
Bearing Installer - Crankshaft Pilot Bearing 3264
Subframe Support Tool 3290
Torque Wrench 1331 5-50 Nm VAG1331
Bushing Driver - Selector Shaft T10168
Locking Sleeve Drift T10169 or Locking Sleeve Drift T10362, refer to Fig 10
Breather Tube Tool T10203
-1- Puller - Kukko Internal - 14-19 mm 21/2
-1- Puller - Kukko Internal - 20-30 mm 21/4
-4- Puller - Kukko Counterstay 22/2
Thread adaptor from Puller - Kukko Counterstay 22/1

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Installation Position Of Lock Elbow

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The mark on the locking elbow -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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The locking elbow must be unlocked when being installed.

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

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A -

Puller - Kukko Internal - 14-19 mm, for example 21/2

B -

Counter Support, for example, Puller - Kukko Counterstay 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 transmission housing on Press Plate VW401 and Press Plate VW402 in such a way so that the alignment sleeves inside the transmission housing do not get damaged.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Locking bolt 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Puller - Kukko Internal - 20-30 mm, for example 21/4

B -

Counter Support, for example, Puller - Kukko Counterstay 22/2

NOTE:

The needle sleeve will get damaged when it is removed and must be replaced.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Support the transmission housing with the Press Piece - 37 mm VW416B directly under the bearing mount.

Fig 15: Identifying Selector Shaft Bushing, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the thread adapter from Puller - Kukko Counterstay 22/1 -arrow-.

-- Hold the spindle on the Subframe Support Tool 3290 steady and turn the nut -B-.

A -

Puller - Kukko Internal - 14-19 mm, for example Kukko 21/2

Fig 16: Driving Bearing Bushing For Selector Shaft In To Tool Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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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-- Using the Bearing Installer - Crankshaft Pilot Bearing 3264, drive in the sealing plugs to dimension -a- approximately 3 mm below the upper edge of the housing.