Transmission, Disassembling And Assembling

Special tools and workshop equipment required 

• 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 
• Bracket - Multiple Use: 30-211A 
• Bearing Installer - Multiple Use: 32-111 
• Assembly Tool Kit - Press Piece 2: T10030/4  from the Hydraulic Press - Bushing Tool Kit: T10030 
• Press Piece - 37mm: VW416B 
• Puller - Transmission Gears: T10408 
• Thrust Pieces: T10408/2 
• Spacer Plate: T10408/3 
• M7 x 35 hex bolts with washers (components of the Puller - Transmission Gears: T10408  )
• Support Bridge: T10323 
• Rear Wheel Bearing Kit - Piece 7: 3253/7 
• Press Piece - Multiple Use: VW433 
• Torque Wrench 1332 40-200Nm: VAG1332 
• -2- Puller: VAS251417  (quantity: 2)
• Inductive Heater: VAS6414 
• Sealing Compound
• Select the sealing compound. Refer to the Parts Information.
• M8 x 100 mm stud bolt

Transmission Housing Cover, Transmission Housing, Gearshift Shaft with Gearshift Cover, Input Shaft, Output Shaft, Differential and Gearshift Mechanism, Removing and Installing

Transmission, Disassembling 

-- Remove the clutch release lever, the release bearing and the guide sleeve. 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 

-- Secure the bolt from the Bracket - Multiple Use: 30-211A  with the nut -A-.

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 Transmission Support: VW353  .

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-- Place the Drip Tray underneath.

-- Open the oil filler plug and the oil drain plug.

-- Drain the transmission fluid.

-- 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.

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

-- Engage the 5th gear in direction of -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 both bolts -arrows- for the reverse shaft support.

-- Now remove the third bolt -arrow- for the reverse shaft support.

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

-- Move the gearshift shaft into neutral and remove the gearshift shaft with the gearshift cover. Remove the bolts -arrows- and pull the gearshift shaft out of the transmission housing.

-- Remove the cover -A- and pivot pin -B- on the bottom of the transmission.

-- Remove the pivot pins -A- on top side of transmission and bolts -B- for transmission housing to clutch housing in area of differential.

-- Remove the bolts -A- that connect the clutch and transmission housing.

-- Remove both flange shafts.

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

Remove Following Components Together with Transmission Housing:

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• 5th/6th gear synchronizer hub
• 6th gear
• 5th gear

• Both : T10408/3  must be attached to the 5th gear.
• The Plates must always be arranged above the two housing ribs that are opposite each other -arrows-.

Use the : T10408  with the Following Special Tools:

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• Thrust Pieces: T10408/2 
• Spacer Plate: T10408/3 
• Puller - VAS251417 (quantity: 2)

-- Fasten the : T10408  in the threaded holes for the transmission housing cover with the bolts -A-.

A -  M7 x 35 Hex Bolts with Washers

Tightening specification: 18 Nm

-- Place the : T10408/2  on the shafts.

-- Mount the VAS251417 -A-.

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-- Remove the 5th/6th gear synchronizer hub, the 6th gear, the 5th gear and the transmission housing by tightening the spindles -A- (approximately ¹ /₂ turn) and alternating from side to side.

-- If necessary, warm the 5th gear and the 6th gear slightly using the : VAS1978/14A  .

-- Remove the nuts -B- from the bearing mount/output shaft.

-- Remove the shift forks -A- together with the gearshift rails.

Transmission with Reverse Gear Assembly -arrow- 

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-- Remove the shift mechanism/reverse gear -B- (see the previous image).

-- Remove the reverse gear -A-, the input shaft -B- and the output shaft -C-, one after the other, from the clutch housing.

Transmission with Reverse Gear Locking Collar -arrow- 

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-- Remove the input shaft -1-, output shaft -2- and reverse shaft -3- from the clutch housing together.

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Continuation for All 

-- Remove the differential.

Transmission, Assembling 

-- Install the differential.

-- Replace the sealing rings -arrows- for the bearing mount/output shaft after removing.

Transmission with Reverse Gear Assembly -arrow- 

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-- Insert the input shaft -1- and output shaft -2- together.

-- Tighten the nuts for the bearing mount / output shaft.

-- Install the reverse gear wheel -3- on the needle bearing inside the clutch housing.

The collar -arrow- faces away from clutch housing.

-- Make sure the reverse shaft -4- is complete. Refer to OVERVIEW - REVERSE SHAFT WITH REVERSE GEAR ASSEMBLY . Do not mount the support on the reverse shaft.

-- Install the reverse shaft into the clutch housing.

-- Clean all threaded holes in reverse shaft supports of locking compound; cleaning can be done with a thread tap.

-- Place the reverse shaft support on the reverse shaft.

-- Install the reverse gear shift fork -1- with the support for the reverse gear shift fork -2-, the spring -3- and the sliding piece -4-.

Reverse Gear Installation Position 

-- Fasten the shift mechanism/reverse gear -A-. Refer to OVERVIEW - INPUT SHAFT, OUTPUT SHAFTS, DIFFERENTIAL AND SHIFT RODS .

-- Install the shift forks -B- together with the gearshift rails.

The pin for the reverse gear support -C- is in front of the gearshift rails.

Transmission with Reverse Gear Locking Collar -arrow-

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• Clean all threaded holes in reverse shaft supports of locking compound; cleaning can be done with a thread tap.

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• Position the input shaft -1-, output shaft -2- and reverse shaft -3- facing each other as shown on, for example, a workbench.
• Hold the input shaft -1- in place with the : 3435  .
• The splines -arrow- on the reverse gear locking collar face the reverse gear assembly.

-- Insert the input shaft -1-, output shaft -2- and reverse shaft -3- together.

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The output shaft -2- contacts the differential.

-- So that the output shaft -2- can be inserted into the clutch housing, have a second technician turn the differential if necessary.

-- Tighten the nuts for the bearing mount / output shaft.

-- Mount the shift forks -A- together with the gearshift rails.

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The reverse gear support -B- is located in front of the gearshift rails.

• The gearshift rail for the reverse gear engages in the reverse gear locking collar -arrow-.

Continuation for All 

-- Install the M8 x 100 stud bolts -A- into reverse shaft support so that the shaft is aligned after fitting the transmission housing.

-- Align the gearshift rails.

-- Apply Sealing Compound evenly onto the sealing surface of the clutch housing.

-- Install the transmission housing and tighten it secure.

Install the bolts for the reverse shaft support -arrow- as follows:

-- Install the bolt -a-.

-- Remove the stud bolts -A- (see upper illustration).

-- Install the bolt -c-.

Tightening sequence: 

-- Tighten the bolt -a- (see upper illustration).

-- Tighten the bolt -b-.

-- Tighten the bolt -c- (see upper illustration).

-- Install the pivot pin -arrow- for the shift forks. To do so, align the shift mechanism with a screwdriver so that the respective pivot pin can be installed.

-- Apply the Sealing Compound evenly on the sealing surface on the cap.

-- Install the gearshift shaft cover.

Install the gearshift shaft with the gearshift cover as follows:

-- Move the gearshift rails to neutral.

-- Apply Sealing Compound evenly onto the sealing surface of the gearshift cover.

-- Move the gearshift shaft into neutral.

-- Position the gearshift shaft so that the shift finger -arrow- is inserted into the gearshift rails.

-- Tighten the gearshift cover for the gearshift shaft.

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

-- Install both flange shafts with the pressure springs, thrust washers and tapered rings. Refer to OVERVIEW - DIFFERENTIAL .

Tightening Specifications 

• Refer to OVERVIEW - TRANSMISSION HOUSING AND GEARSHIFT MECHANISM 
• Refer to OVERVIEW - INPUT SHAFT, OUTPUT SHAFTS, DIFFERENTIAL AND SHIFT RODS 
• Refer to OVERVIEW - DIFFERENTIAL