Transmission, Disassembling And Assembling: Notes

Remove and Install Transmission Housing, Shift Mechanism, Input Shaft, Output Shafts, Differential, Selector Rods and Bevel Box, if Necessary.

Special tools and workshop equipment required

Holding Plate VW309A
or Holding Plate VW309A
Holding Fixture VW313
Transmission Support VW353
Press Piece - Multiple Use VW455 or Press Piece - Front Wishbone 3160
Slide Hammer Set VW771
-1- Puller - Kukko Internal - 12-16mm Kukko 21/01
-3- Puller - Kukko Quick Action Separating Tool - 5-60mm Kukko 17/0
-4- Puller - Kukko Counterstay Kukko 22/1
Bracket - Multiple Use 30-211A
Seal Installer - Drive Flange T10143 or Seal Installer - Output Shaft Oil Seal T10180
Locking Sleeve Drift T10169
or Locking Sleeve Drift T10362. Refer to Figure
Seal Installer - Drive Axle T40008
Torque Wrench 1331 5-50Nm VAG1331
Hot Air Blower VAG1416
Pry Lever 80-200
Drip Tray VAG1306
or Shop Crane - Drip Tray VAS6208
Sealant
Allocation.

Transmission, Disassembling

Fig 1: Identifying Transmission Secured To Assembly Stand With Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the transmission on the Transmission Support VW353 -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 gear oil from manual transmission.

Fig 2: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove right flange shaft countersunk screw with Socket And Key.

-- Remove the 4 bolts -arrows- attaching the bevel box to the manual transmission (only 3 bolts are shown in the illustration).

-- Carefully press bevel box or front axle differential lock off manual transmission while protecting it against falling through.

-- Note the transportation of the front axle differential lock. Refer to .

FWD Transmission without Front Axle Differential Lock

Fig 3: Identifying Flange Shaft, Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right flange shaft (the illustration shows the left flange shaft).

-- Remove the flange shaft and the pressure spring.

Continuation for All

Fig 4: Identifying Slave Cylinder With Release Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 5: Identifying The Transmission Neutral Position Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Make sure the Gearshift Shaft is Not Blocked by the Lock Elbow -arrow-.

Fig 6: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 7: Securing Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left flange shaft bolt. To do this, install two bolts in the flange and counterhold it using a tire iron.

Fig 8: Identifying Flange Shaft, Installation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the flange shaft and the pressure spring.

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

Fig 9: Identifying Interior Clutch Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Lock the input shaft as follows:

Fig 10: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The Stub Shaft Splines On the Input Shaft Has 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 11: Identifying Separating Tool -A- And Sleeve 3160

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

The back of the Separating Tool - 5-60mm 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.