Transmission, Disassembling And Assembling

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

Special tools and workshop equipment required

Holding Plate: VW309A
Holding Fixture: VW313
Transmission Support: VW353
Press Piece - Multiple Use: VW455 or Press Piece - Front Wishbone: 3160
Slide Hammer Set: VW771
Internal Puller (kukko 21/01): VAS251603
Splitter (Kukko 17/0): VAS251407
Counter Support: VAS251621
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
Shop Crane - Drip Tray: VAS6208
Sealing Compound: AMV 188 200 03

Transmission, Disassembling

Fig 1: Identifying Transmission Secured To Assembly Stand With Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the transmission on the : 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 : VAS6208 underneath.

-- Drain gear oil from manual transmission.

AWD 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.

Fig 3: 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 4: 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 5: Identifying Back-Up Lamp 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 : 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 6: 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 7: Identifying Flange Shaft

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 8: 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 9: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The stub shaft splines on the input shaft has different lengths on the transmission.

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

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then tension the Splitter -A- (for example, Splitter (Kukko 17/0): VAS251407 ) behind the input shaft splines.

The back of the Separating Tool - 5-60mm must touch the Press Piece - Multiple Use: VW455 or the : 3160 free-of-play.

NOTE:

Metal and plastic covers are installed for the input shaft.

The Locking Ring Has Been Discontinued Together with the Plastic Cover for the Input Shaft.

Fig 11: Identifying Input Shaft Sealing Cap Types

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-I- = Steel cover for the input shaft with locking ring -A-
-II- = Plastic cover for the input shaft without locking ring

Metal Cover

Fig 12: Identifying Transmission Housing Without Sealing Cap Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the cap/input shaft circlip -A-.

-- Pierce the rubber piece in the center of the cover -C- using a Screwdriver.

Fig 13: Identifying Support, Internal Puller & Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

There is a risk of damaging the components under the cap.

-- Remove the cover from the transmission housing.

A - Counter Support, for example, Counter Support (Kukko 22/1): VAS251621

B - 8 to 12 mm Internal Puller, for example, Internal Puller (kukko 21/01): VAS251603

NOTE:

Pry the cap -1- off with a screwdriver -2-.

Fig 14: Prying The Cover Out

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plastic Cover

Fig 15: Identifying Screwdriver To Remove Tabs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Carefully remove all tabs -A-. Do not damage the transmission housing when doing so.

-- Remove the cap -A-.

Fig 16: Identifying Screwdriver To Pry Out Sealing Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Make sure the individual parts of the cover are removed, if necessary.

Continuation for All

Fig 17: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Hold one end of the locking ring secure with the Screwdriver -A-.

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

-- Pry out the rest of the locking ring using the Screwdriver -B-.

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

Fig 18: Identifying Transmission Housing To Clutch Housing Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install : VW771/40 into the threaded hole in the transmission housing.

-- 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 approximately 10 minutes using a Hot Air Blower, for example, : VAG1416 .

NOTE:

Pry off the transmission housing carefully at the protruding braces using a pry lever and alternating from side to side. Do not damage sealing surface.

-- Remove the transmission housing from the clutch housing in direction of -arrow- using : VW771/40 .

Fig 19: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the Separating Tool -A- and the Press Piece - Multiple Use VW455 or the : 3160 from the input shaft.

Fig 20: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 gearshift rods -2- -arrow A-.

Fig 21: Identifying Differential & Output Shaft Lifted With Selector Rods

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- At the same time, the second technician lifts the input - reverse- and output shafts for 5th/6th gear and reverse gear -3- together with the gearshift rod out of the clutch housing -arrow B-.

NOTE:

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

-- Remove the input shaft seal.

NOTE:

Replace grooved ball bearing on drive axle after removing. Refer to OVERVIEW - INPUT SHAFT .

Assembling the Transmission

A new grooved ball bearing is pressed onto the input shaft. Refer to OVERVIEW - INPUT SHAFT .
The reverse gear shift fork -1- is placed on the 5th and 6th gear gearshift rod -2-. Refer to the information below.

Fig 22: Identifying Reverse Gear Selector Fork -1- Mounted On Selector Shaft With 5th And 6th Gear Selector Fork -2-
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 23: Identifying Input Shaft, 5th/6th Gear Output Shaft, 5th/6th Gear Gearshift Rod, Reverse Gear Shift Fork And Reverse Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The shift jaw -arrow A- on the reverse gear shift fork faces the outside of the transmission. The shift jaw -arrow B- on the 5th/6th gear gearshift rod must face toward the inside of the transmission.

-- Then install the differential -1-.

Fig 24: Identifying Differential, Input Shaft & Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Hold the 1st through 4th gear output shaft -3- with the gearshift rods -4- in the right hand as illustrated.

-- Lift the differential slightly with your left hand.

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

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

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

-- Place the shafts and the differential in their bearing seats with a second technician.

-- Secure the : 30-211A for the input shaft to the clutch housing.

Fig 25: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

The Grooved Ball Bearing/Input Shaft Only Fits in One Position in the Transmission Housing.

Fig 26: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

There is a flattened area on the grooved ball bearing and the bearing mount.

The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark this flat side with color.

-- Transfer the markings to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (see next figure).

-- 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 approximately 10 minutes using a : Hot Air Blower , for example, : VAG1416 .

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

Apply Sealing Paste: AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

Align the marking on the grooved ball bearing -A- with the marking on the transmission housing -B- and mount the transmission housing.

Fig 27: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the transmission housing and tighten the new bolts -A, B and C-.

Fig 28: Allocation Of Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Transmission with Reinforcement Measures (Manual Transmission 0FB)

Fig 29: Locking Ring 1 for the Grooved Ball Bearing/Input Shaft 2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Redetermine the locking ring -1- for the grooved ball bearing/input shaft -2- :

Check that the input shaft with the : 30-211A is pressed up against the transmission housing.
Determine the thickest locking ring that has not yet been used and install it in the grooved ball bearing/drive axle, starting with the thickest locking ring.

The following locking rings are available. For the part number. Refer to Parts Information.

Circlip Thickness (mm)
2.03	2.09	2.15
2.21	2.27

Continuation for All

-- Install the grooved ball bearing/input shaft locking ring -1-.

Fig 30: Identifying Circlip & Special Tool VW 309

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the : 30-211A for the input shaft.

-- If the retaining sleeve for the gearshift shaft was removed, then install it now all the way onto the tool. Refer to Figure.

-- Turn the transmission so that the opening for the gearshift shaft faces up in the assembly stand.

NOTE:

Use the : 80-200 to press against the spring force of the securing bushing in direction of -arrow- when installing so that the gearshift shaft -1- does not touch the securing bushing -2- when removing.

Fig 31: Securing Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the gearshift shaft -1- into the lower bearing -2- and into the shift forks -3-.

Fig 32: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The cover is not shown in the illustration. Refer to OVERVIEW - TRANSMISSION HOUSING .

-- Push the gearshift shaft -1- against the retaining sleeve -2- in direction of -arrow- and guide is through the shift fork all the way down using the shift finger -3-.

Fig 33: Identifying Selector Shaft Pressed Against Lock Sleeve And Guided Downward With Shift Finger

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The gearshift cover -4- must stand parallel to the bolting surface on the transmission housing.
It must be possible to move the gearshift shaft easily (forward and backward).

NOTE:

If the gearshift cover is at an angle to the bolting surface, then the gearshift shaft is not installed into the lower bearing.

-- Tighten the bolts -3- for the gearshift cover -4-.

Fig 34: Identifying Back-Up Lamp Switch, Mounting Screw, Bolts & Selector Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the locking screw -2-, lock elbow -arrow- must not be installed when doing so.

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

-- Transmission on vehicles with Stop/Start system: install the Transmission Neutral Position Sensor -G701- -arrow- and tighten the screw.

Fig 35: Identifying The Transmission Neutral Position Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the input shaft seal so that it is flush.

Fig 36: Driving In Input Shaft Oil Seal Flush

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the clutch slave cylinder with release bearing. Refer to CLUTCH SLAVE CYLINDER WITH RELEASE BEARING, REMOVING AND INSTALLING .

-- Move the gearshift lever (selector lever) through all the gears.

-- Install the cover as follows:

Cover Differentiation

Fig 37: Identifying Input Shaft Sealing Cap Types

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-I- = metal cover; secured with securing ring -A-.

-II- = plastic cover; without securing ring.

Allocation

Fig 38: Allocation:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Mounting Area for the Cover	Cap	Installation
-Arrow A- = vertical	Made of metal	Refer to Fig 39
-Arrow B- = at an angle	Plastic	Refer to Fig 41

Metal Cover

Fig 39: Identifying Tool Assembly To Install Metal Cap On Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the cap all the way into the transmission housing.

-- Secure the cap with the locking ring -A-.

Fig 40: Identifying Transmission Housing Without Sealing Cap Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plastic Cover

Fig 41: Identifying Tool Assembly To Install Plastic Cap On Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the cap all the way into the transmission housing.

Continuation for All

Always pay attention to the cover allocation. Refer to Fig 38.
Leaks in the case of incorrect installation.
For the correct cap. Refer to the Parts Information.

-- Install the flange shafts with the springs, thrust washers and tapered rings.

Fig 42: Identifying Flange Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

AWD Transmission

Fig 43: Identifying Removal/Installation Right Flange Shaft Countersunk Bolt Using Socket And Key T10107

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Install the Bevel Box/Manual Transmission

-- Coat the splines on the manual transmission differential with Grease For Clutch Disc Shaft Splines: G 000 100 .

-- Slide bevel box or flange shaft front axle differential lock completely onto manual transmission. While doing this, join splines of input shaft/bevel box or front axle differential lock centrally with the differential.

-- Line up the splines on the right flange shaft with the differential bevel gear. Turn the flange shaft if necessary.

-- With proper tooth position and central guiding, the bevel box or front axle differential lock slips up to stop against manual transmission.

NOTE:

Do not pull the bevel box or front axle differential lock with mounting bolts against the manual transmission, otherwise the assembly can tilt and the mounting eyes can break off.

-- Tighten the four bolts -arrows- attaching the bevel box or the front axle differential lock to the manual transmission (only three bolts are shown in the illustration).

-- Tighten the right flange shaft conical head bolt with the Socket Insert.

Tightening Specifications

Refer to OVERVIEW - TRANSMISSION HOUSING AND SELECTOR MECHANISM
Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .
Refer to OVERVIEW - DIFFERENTIAL .