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 Drip Tray underneath.

-- Drain the transmission fluid from the 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 the countersunk bolt for the right flange shaft using the Socket.

-- 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 off the manual transmission while protecting it against falling.

FWD Transmission

Fig 3: Identifying Flange Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the flange shaft with 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 Start/Stop 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 during the Following Step That the Gearshift Shaft Is Not Blocked by the Locking Elbow -arrow-.

Fig 6: 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 locking bushing in the direction of -arrow- so that the gearshift shaft -1- does not touch the locking bushing -2- during removal.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the flange shaft with 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 on the 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 Splines on the Input Shaft Have 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 11: Identifying Separating Tool -A- And Sleeve 3160

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tension the : VAS251407 (Kukko 17-0) -A-, tightly behind the splines on the input shaft.

The rear side of the Splitter must touch the : VW455 or the : 3160 without any 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 12: 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 Cap

Fig 13: Identifying Transmission Housing Without Sealing Cap Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Pierce the rubber piece in the center of the cap -C- with a Screwdriver.

Fig 14: Identifying Support, Internal Puller & Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

There is a risk of damaging the components underneath the cover.

-- Remove the cap from the transmission housing.

A - Counter Support: VAS251621 (Kukko 22-1)

B - Internal Puller: VAS251603 (Kukko 21-01)

NOTE:

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

Fig 15: Prying The Cover Out

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plastic Cap

Fig 16: Identifying Screwdriver To Remove Tabs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Pry out the cap -A-.

Fig 17: 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 18: 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 circlip -C- as follows from the grooved ball bearing for the input shaft/transmission housing:

-- 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 transmission housing bolts -A- from the clutch housing.

Fig 19: 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.

Fig 20: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 .

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

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 Separating Tool -A- and the : VW455 or the : 3160 from the input shaft.

Fig 21: 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 22: 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 shaft, reverse shaft and output shaft 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 .