Volkswagen Workshop Service and Repair Manuals

Removing –  Secure gearbox to assembly stand using bolts -arrows-.   Note

If one of the bolting holes does not contact the gearbox support, lay a washer between the hole and the gearbox support. –  Rotate gearbox on assembly stand so that oil drain plug is below. –  Place drip tray underneath. –  Drain gear oil from gearbox.

Gearbox for four-wheel drive –  Remove right flange shaft countersunk bolt with socket. –  Remove the 4 connecting bolts -arrows- for bevel box to gearbox (only 3 are visible in figure). –  Carefully press bevel box off gearbox, taking care that it does not fall. Gearbox for front-wheel drive

–  Remove right flange shaft (fig. shows left flange shaft). Continuation for all

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

–  Remove bolts -B-, which secure gearbox housing to clutch housing.   Note One bolt -arrow- is located outside of bolting flange. –  Lock input shaft. The lengths of the splines on the input shaft differ to those of the gearbox.

–  Set either installing sleeve -VW 455- over input shaft on clutch housing

–  or set sleeve -3160- over input shaft on clutch housing –  Clamp splitter-A-, e.g. -Kukko 17/0-, behind notch in splines of input shaft. The back side of the splitter must rest against installing sleeve -VW 455- or sleeve -3160- without play.

–  Remove left flange shaft.

–  Gearboxes for vehicles with start-stop system: remove gearbox neutral position sender -G701--arrow-.

During the following steps, ensure that the selector shaft is not blocked by the angled rod -arrow-. –  Move selector shaft to neutral. –  Remove locking bolt -2-. –  Then remove bolts -3-. –  Remove reversing light switch -F4--1-. –  Pull selector shaft -4- out of gearbox housing.

Sheet metal cover plate –  Remove retaining ring -A- for input shaft sealing cover.

–  Pierce rubber in centre of cover -C- with a screwdriver. –  Pull sealing cover out of gearbox housing. A -  Counter support, e.g. -Kukko 22/1- B -  Internal puller, 8 … 12 mm, e.g. -Kukko 21/01-

Plastic cover plate Carefully remove all lugs -A-. When doing this, do not damage gearbox housing.

–  Lever out cover. l  Ensure that cover plate components are removed where necessary. Continuation for all

Remove retaining ring -C- from deep groove ball bearing of input shaft in gearbox housing as follows: –  Hold one end of retaining ring with screwdriver-A-. –  Using a screwdriver, -B-, lever other end out of groove in deep groove ball bearing -direction of arrow-. –  Using screwdriver-B-, lever out securing ring further.

–  Remove securing bolts -A- for gearbox housing to clutch housing.

–  Screw adapter VW 771/40 into threaded hole of gearbox housing. –  Heat gearbox housing using e.g. hot air blower -V.A.G 1416- in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100°C. –  Using multi-purpose tool VW 771/1, pull gearbox housing off clutch housing in -direction of arrow-.   Note If necessary, carefully apply assembly lever on alternating sides at overhanging housing shoulders along perimeter, being careful not to damage sealing surfaces.

–  Remove splitter-A- and installing sleeve VW 455 or sleeve -3160- from input shaft. To remove shafts from clutch housing, a second mechanic is required.

–  With left hand, raise differential -1-. With right hand, lift output shaft for 1st to 4th gear together with selector rods -2--arrow A-. –  At same time, second mechanic lifts input shaft, reverse shaft and output shaft for reverse, 5th and 6th gears -3- together with selector rods out of clutch housing -arrow B-.   Note After shafts are lifted, differential may be set back in clutch housing if desired. –  Lever out input shaft oil seal using oil seal extractor lever -VW 681-.   Note Always renew deep groove ball bearing on input shaft → Item.