Volkswagen Workshop Service and Repair Manuals

Removing –  Remove clutch release lever, release bearing and guide sleeve → Chapter. l  Bearings of input shaft and output shaft must not be damaged when 5th gear is 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- –  Lock bolt of support bridge -30-211A- with nut -A-. Underneath bearing support for output shaft: t  Support device -T10323- t  Assembly tool -3253/7- t  Thrust piece -VW 433-

–  Secure gearbox on gearbox support -VW 353-. –  Place drip tray -V.A.G 1306- underneath. –  Remove oil filler plug and oil drain plug. –  Drain gear oil.

–  Remove gearbox housing cover -arrow-.

Remove selector fork for 5th gear as follows: –  Cover openings with a cloth. –  Move selector fork -1- to neutral position. –  Remove bolt -2- with selector fork for 5th gear. –  Then remove both bolts -arrows- for pivot pins. –  Pull out pivot pins. –  Remove selector fork. –  Spring -3- and locking collar -4- do not need to be removed.

–  Remove bolts -A- for synchro-hub and gear wheel for 5th gear. To do this, engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  After both gears are engaged, the input shaft and output shaft are locked. The synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.   Note If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.

–  Remove both bolts -arrows- for reverse shaft support bracket.

–  Now remove 3rd bolt -arrow- for reverse shaft support bracket.

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

–  Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position. Then remove bolts -arrows- and pull selector shaft out of gearbox housing.

–  Remove cover plate -A- and pivot pins -B- from underside of gearbox.

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

–  Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing.   Note Do not remove nuts -B- for output shaft bearing support.

–  Remove both flange shafts. –  Remove flange shafts together with springs, thrust washers and tapered rings.

Pull off following components together with gearbox housing: t  Synchro-hub for 5th gear t  Gear wheel for 5th gear l  Both grips -T10408/3- must be secured on gear wheel for 5th gear. l  The grips must always be positioned above the two housing ribs, which are located opposite each other -arrows-.   Note t  There is a needle bearing beneath the gear wheel for 5th gear. t  Secure the grips so that the bearing does not come in contact with the gear wheel for 5th gear when the gearbox housing is pulled off.

Use puller plate -T10408- in conjunction with following special tools: t  Thrust pieces -T10408/2- t  Grips -T10408/3- t  Puller Kukko 18/1 –  Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. A -  Hexagon bolts M7 x 35 with washers Torque setting 18 Nm –  Place thrust pieces -T10408/2- on shafts.

–  Install pullers Kukko 18/1-A-. –  Pull off 5th gear synchro-hub, gear wheel for 5th gear and gearbox housing by alternately tightening spindles -A- approx. 1 2 turn. –  If necessary, heat 5th gear wheel slightly using hot air blower -V.A.G 1416-, for example.

–  Remove nuts -B- for output shaft bearing support.

–  Remove selector forks -A- together with selector plates. –  Unbolt reverse gear selector mechanism -B-.

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