Volkswagen Workshop Service and Repair Manuals

Removing –  Remove clutch release lever and release bearing → Chapter. l  Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.

l  Therefore, following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353-: Underneath input shaft: t  Support bridge -30-211A- t  Thrust piece -32 - 111- t  Thrust piece -T10030/4- l  The input shaft can be supported by the thrust piece -32 - 111- only at a later point. Underneath bearing support for output shaft: t  Support device -T10323- t  Assembly tool -3253/7- t  Thrust piece -VW 433- The illustration shows a gearbox for front-wheel drive.

–  Secure gearbox on gearbox support -VW 353-

–  Remove gearbox housing cover -arrow-. –  Remove cover, if necessary carefully levering up all around along protruding housing flange and alternating between sides, being careful not to damage sealing surfaces.

–  Check whether puller hooks -T10040/2A- can be inserted correctly under 5th gear wheel.

Puller hooks -T10040/2A- cannot be inserted correctly.
-A- Puller hooks -T10040/2A- make contact too soon with: t  gearbox housing wall t  ribs in gearbox housing under gear wheel	Removal of “synchro-hub 5th/6th gear”, “6th gear wheel”, “ 5th gear wheel” and “gearbox housing” together → Chapter
-B- Puller hooks -T10040/2A- come into contact with ribs in gearbox housing below gear wheel.

Puller hooks -T10040/2A- cannot be inserted correctly.

5th and 6th gears can be removed separately, ⇒ from → Fig.

Remove 5th and 6th gears individually –  Remove selector fork for 5th and 6th gears as follows: –  Cover openings with a cloth. –  Engage 5th gear -arrows 1- and -2-. –  Remove selector jaw for 5th and 6th gears -bolt A-. –  Then remove both bolts -B- for pivot pins. –  Pull out pivot pins. –  Remove selector fork for 5th and 6th gears.

–  Remove -bolts A- for inner bearing races from input and output shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and -arrow 3-. –  Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened.   Note If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.

–  Pull off 6th gear wheel with inner race of cylindrical roller bearing for output shaft. A -  Two arm puller, e.g. -Kukko 20/10- B -  Hexagon bolt, M10 x 20, 17 mm AF   Note 6th gear wheel with cylindrical roller bearing inner race can also be pulled off using two arm puller -T10040- and puller hooks -T10040/2A-. –  Heat gear wheel slightly with hot air blower -V.A.G 1416- if necessary. Pull off synchromeshed gear for 6th gear together with cylinder roller bearing inner race for input shaft, thrust washer and synchro-ring for 6th gear only or together with synchro-hub for 5th and 6th gears, needle bearing inner race for 6th gear and synchro-ring for 5th gear.   Note From gearbox date 26 05 8, a wave spring washer is installed below the synchro-ring for 5th gear and above the synchro-ring for 6th gear → Item and → Item. Use puller -T10309-.

–  First set half sleeve -T10309/1- between output shaft -A- and support for selector fork for 5th and 6th gear -B-. l  The half sleeve -T10309/1- must be positioned beneath the synchro-ring. –  Turn half sleeve -T10309/1- to opposite side -direction of arrow-.

–  Set threaded insert -T10309/3- in half shell. –  Now fit second half shell -T10309/1- and set tube -T10309/2- over assembly. –  After parts are pulled off, check synchro-hub for damage. –  Renew synchro-ring. –  Now remove sleeve from 5th gear wheel.

–  Pull off gear wheel for 5th gear. –  First set up puller hooks -A-. -B- = Thrust piece -T10040/3- or Thrust plate -40 - 105-   Note When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off gear wheel for 5th gear, examine for damage.