Transmission Housing Cover And 5TH/6TH Gear, Removing

Special tools and workshop equipment required 

• Holding Plate: VW309 
• or Holding Plate: VW309A 
• Transmission Support: VW353 
• Bearing/Bushing Installer - Multiple Use: VW295 
• Bearing Driver - Multiple Use: VW244B 
• Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A  , for example
• Torque Wrench 1331 5-50Nm: VAG1331 
• Support Bridge: T10323 
• Rear Wheel Bearing Kit - Piece 7: 3253/7 
• Press Piece - Multiple Use: VW433 
• Press Piece - Multiple Use: 40-105 
• Torque Wrench 1332 40-200Nm: VAG1332 
• Bracket - Multiple Use: 30-211A 
• Bearing Installer - Multiple Use: 32-111 
• Assembly Tool Kit - Press Piece 2: T10030/4 
• Press Piece - 37mm: VW416B 
• Puller - Transmission Gears: T10309A 
• Puller - Two Arm: T10040 
• With the Puller - Two Arm w/Thrust Piece: T10040/2A 
• Or for the 6th gear: Two-Arm Puller: VAS251001 

-- Remove the clutch release lever and release bearing. Refer to CLUTCH RELEASE MECHANISM, SERVICING .

• Do not damage the bearing for the input and output shafts when removing and installing 5th/6th gear.
• When securing the transmission to the : VW353  , the following tools must be mounted for support:
  Fig 1: 30-211A, VW 353 & T10323

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Under the Input Shaft:

• Bracket - Multiple Use: 30-211A 
• Bearing Installer - Multiple Use: 32-111 
• Assembly Tool Kit - Press Piece 2: T10030/4 

• The input shaft may only be supported by the Bearing Installer - Multiple Use: 32-111  at a later time.

Under the Output Shaft Bearing Mount:

• Support Bridge: T10323 
• Rear Wheel Bearing Kit - Piece 7: 3253/7 
• Press Piece - Multiple Use: VW433 

-- Secure the transmission on the : VW353  .

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-- Remove the transmission housing cover -arrow-.

-- Remove the cover; if necessary, carefully pry it out of the protruding ridges all the way around by alternating from side to side. Do not damage the sealing surfaces while doing so.

-- Make sure the : T10040/2A  can be installed correctly under the 5th gear.

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Puller - Two Arm w/Thrust Piece: T10040/2A  cannot be installed correctly.
-A- : T10040/2A  prematurely touches the: Transmission housing wall The ribbing in the transmission housing under the 5th gear.	"Combined" removal of: "5th/6th gear synchronizer hub", "5th gear" and "transmission housing". Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .
-B- : T10040/2A  touches the ribbing in the transmission housing under the 5th gear.

Puller - Two Arm w/Thrust Piece: T10040/2A  can be installed correctly.
5th/6th gear can be removed separately. Refer to Fig 2.

5th/6th Gear, Removing Separately 

-- Remove the 5th/6th gear shift fork as follows:

-- Cover the openings in the transmission housing with a cloth.

-- Engage the 5th gear -arrows 1 and 2-.

-- Remove the 5th/6th gear shift jaw -bolt A-.

-- Then remove both -B bolts- for the pivot pins.

-- Remove the pivot pin.

-- Remove the 5th/6th gear shift fork.

-- Remove the -A bolts- for the bearing inner races from the input and output shafts. To do so, engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3-.

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-- The input shaft and the output shaft are blocked after both gears are engaged. Both bolts can be loosened now.

-- Remove the 6th gear with the inner race/cylindrical roller bearing for the output shaft.

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A -  Two-Arm Puller, for example, Two-Arm Puller : VAS251001 

B -  M10 x 20 Hex Bolt, 17 mm

-- If necessary, warm the gear slightly using the : VAS1978/14A  , for example.

Remove the 6th Gear Assembly Alone with the Input Shaft Inner Race/Cylindrical Roller Bearing, Thrust Washer and 6th Gear Synchronizer Ring, or Remove the 6th Gear Assembly Together with the 5th/6th Gear Synchronizer Hub, 6th Gear Needle Bearing Inner Race and 5th Gear Synchronizer Ring. 

Use the Puller - Transmission Gears: T10309A 

-- First insert the Half Shell: T10309/1  between the output shaft -A- and the mount for the 5th/6th gear shift fork -B-.

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• The : T10309/1  must be placed under the synchronizer ring.

-- Press the half shell into the end position, if necessary.

-- Turn the : T10309/1  onto the opposite side in the direction of -arrow-.

-- Insert the : T10309/3  into the : T10309/1  .

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-- Insert the second : T10309/1  and put the : T10309/2  over the tool.

-- Check the synchronizer hub for damage after the removal procedure.

-- If necessary, replace the synchronizer ring.

-- Now remove the sleeve from the 5th gear.

-- Remove the 5th gear.

-- Insert the hook -A-.

-B- = : T10040/3 

or

: 40-105