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 - 37mm :VW416B
Guide Pin :VW436A
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 5-50Nm :VAG1331
Bushing Driver - Selector Shaft :T10168
Locking Sleeve Drift :T10169 or Locking Sleeve Drift :T10362 . Refer to Fig 10
Breather Tube Tool :T10203
Internal Puller :VAS251603 , or for example the Internal Puller (Kukko 21/2) :VAS251605
Internal Puller (Kukko 21/4) :VAS251609 , or for example the Internal Puller :Kukko 21/4
Counter Support (Kukko 22/2) :VAS251623 , or for example Puller - Kukko Counterstay :Kukko 22/2
Thread adapter from Counter Support :VAS251621 , or for example Counter Support :Kukko 22/1

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview and parts information prior to starting procedure.

Mandatory Replacement Parts

Bolts - For Transmission Housing
Seal - Oil Drain Plug to Transmission Housing
Seal - Back-Up Lamp Switch to Transmission Housing
Seal - Oil Filler Plug to Transmission Housing
Needle Sleeve - For Reverse Shaft

Removing the Cover A

Fig 1: 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 the direction of -arrow-.

Installing the Cover

Fig 2: Identifying Tool To Install Cap

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Removing the Locking Elbow for the Gearshift Shaft

Fig 3: Removing Lock Elbow For Selector Shaft

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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-.

Installed Position: Locking Elbow

Fig 4: Installation Position Of Lock Elbow

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Drive Lock Elbow arrow for Selector Shaft in up to Tool Stop.

Fig 5: Inserting Tool T10203

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NOTE:

The locking elbow must be unlocked when being installed.

Removing the Shift Rod Bearing Bushing

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

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A - Internal Puller (Kukko 21/4) :VAS251609 , or Puller - Kukko Internal - 14-19mm, for example the :Kukko 21/2

B - Counter Support (Kukko 22/2) :VAS251623 , or for example Puller - Kukko Counterstay :Kukko 22/2

Installing the Shift Rod Bearing Bushing All the Way onto the Tool

Fig 7: Inserting Tool T10168

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing the Retaining Sleeve A from the Transmission Housing

Fig 8: Pressing Lock Sleeve Off With Transmission Removed

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-- Place transmission housing on :VW401 and press plate :VW402 in such a way so that the alignment sleeves inside the transmission housing do not get damaged.

Removing the Retaining Sleeve on a Transmission Not Disassembled Using the 10-15.

Fig 9: Removing The Retaining Sleeve On A Non-Disassembled Transmission

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Locking bolt and selector shaft removed.

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

Lock Sleeve Differentiation

Fig 10: Identifying Lock Sleeve Differentiation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The Following Lock Sleeves may be Installed:

Retaining sleeve with a shoulder -arrow 1-

Retaining sleeve without a shoulder -arrow 2-

Retaining Sleeve
With Shoulder	Without Shoulder
	Different versions
Installing. Refer to Fig 12.	Retaining sleeve "02T". Refer to Fig 11.	Retaining sleeve "02Q". Refer to Fig 11.

Allocate the components.

Retaining Sleeve 02T and Retaining Sleeve 02Q

Fig 11: Retaining Sleeve "02T" and Retaining Sleeve "02Q"

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Drive in the retaining sleeve "02T". Refer to Fig 13.

Drive in the retaining sleeve "02Q". Refer to Fig 12.

Drive in the Retaining Sleeve with the Shoulder and the Retaining Sleeve 02Q without a Shoulder

Fig 12: Identifying Tools To 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.

Drive in the retaining sleeve all the way onto the tool

Drive in the Retaining Sleeve 02T without a Shoulder.

Fig 13: Identifying Tools To 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.

Drive in the retaining sleeve all the way onto the tool

Removing the Reverse Shaft Needle Sleeve from the Transmission Housing

Fig 14: Removing the Reverse Shaft Needle Sleeve from the Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Internal Puller (Kukko 21/4) :VAS251609 , or for example the Internal Puller :Kukko 21/4

B - Counter Support (Kukko 22/2) :VAS251623 , or for example Puller - Kukko Counterstay :Kukko 22/2

NOTE:

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

Installing the Needle Sleeve A into the Transmission Housing

Fig 15: Installing the Needle Sleeve A into the 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 :VW416B directly under the bearing mount.

Removing the Selector Shaft Bearing Bushing

Fig 16: Selector Shaft Bearing Bushing Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the thread adapter from the :VAS251621 , or for example Counter Support :22/1 -arrow-.

-- Hold the spindle on the :3290 steady and turn the nut -B-.

A -

:VAS251603 , or for example the Internal Puller (Kukko 21/2) :VAS251605

Fig 17: Installing the Gearshift Shaft Bearing Bushing A All the Way Onto the Tool

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Fig 18: Removing the Plug 1

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

Fig 19: Installing the Plug 1

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