Volkswagen Workshop Service and Repair Manuals

Removing

–  Secure gearbox to repair stand Engine and gearbox support -VW 540--arrows-. –  Place drip tray -V.A.G 1306- underneath. –  Drain gear oil.

–  Remove clutch release lever -A- together with release bearing and guide sleeve -arrows-. –  Remove right flange shaft securing bolt -B-. –  Screw two bolts into flange and counterhold flange shaft using a lever. –  Remove flange shaft along with spring, thrust washer and tapered ring.

–  Unbolt gearbox housing cover -arrow- and carefully pull it off.

–  Pull out pivot pin -1- for 5th gear -2- and remove selector fork. –  Remove securing clip -3- for 5th gear synchro-hub. –  Remove locking collar with synchro-hub, synchromeshed gear for 5th gear with synchro-ring and needle bearing from output shaft. –  Remove securing clip -4- for gear wheel for 5th gear and remove gear wheel.

–  Remove bearing mounting securing bolts -A- from input and output shafts. –  Unscrew hexagon collared nut -B- for securing reverse gear selector mechanism. –  Remove securing bolt for left flange shaft -C- by screwing two bolts into flange and counterholding flange shaft with a lever. –  Pull out flange shaft -C- with spring. –  Turn gearbox in support bracket so that clutch housing is upwards. –  Remove securing bolts from clutch housing side for securing clutch housing to gearbox housing. –  Remove clutch housing, if necessary carefully levering up all around along protruding housing flange and alternating between sides, being careful not to damage sealing surfaces. –  Do not cant the clutch housing. This prevents damage to roller bearings and their bearing seats on the input and output shafts.

–  Remove differential -A- from gearbox housing.

–  Then remove oil collector -A- and oil guide -B- with magnet from gearbox housing.

–  Remove selector shaft with selector cover -A-. Place selector shaft in neutral. Then remove bolts -arrows- and pull selector shaft out of gearbox housing. –  Remove pivot pins -B- located on underside of gearbox. –  Remove reversing light switch -C-.

–  Remove bolt -A- for securing reverse gear wheel shaft. –  Remove pivot pins -B- located on bottom of gearbox.   Note Do not remove cover plate -arrow- when dismantling gearbox.

–  Press out input shaft, output shaft with bearing mounting, selector mechanism (selector forks) and reverse gear together.   Note t  Position gearbox housing so that dowel sleeves in the gearbox will not be damaged. t  When pressing out, get help from second mechanic to ensure components do not fall out. –  Press input shaft and output shaft off bearing mounting with deep groove ball bearing → Fig..