Volkswagen Workshop Service and Repair Manuals

Dismantling

–  Secure on gearbox support -3221- or on gearbox support -3221A--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 2 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 and 6th gear selector fork -2- and remove selector fork.

–  Remove bolts -A- for inner bearing races on input and output shafts, engaging 5th gear -arrow 1- and 1st gear -arrows 2- and -3-. –  Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened.   Note t  If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser. t  Pull off gear wheel for 6th gear with three arm puller -Kukko 30/1-. t  If necessary, gear wheel for 6th gear can be pulled off to stop on spindle with two arm puller -Kukko 204/2-. Then pull off further with three arm puller -Kukko 30/1-.

–  Pull off gear wheel for 6th gear with inner race of cylindrical roller bearing for output shaft. A -  Three arm puller -Kukko 30/1- B -  Hexagon socket head bolt -M8 x 15-

–  Tighten splitter -Kukko 17/1--A- behind constant mesh teeth of synchromeshed gear for 6th gear (not dog teeth) -arrow-. A -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1- B -  Hexagon socket head bolt -M8 x 15- C -  Puller -Kukko 18/1- –  Pull off gear wheel for 6th gear with inner race of cylindrical roller bearing for input shaft and thrust washer. –  Remove locking collar for 5th and 6th gears with locking pieces.

–  Tighten splitter -Kukko 17/1--A- below synchro-ring for 5th gear -1-. This presses synchro-ring against synchro-hub -2-. A -  Splitter, 12 … 75 mm, e.g. -Kukko 17/1- B -  Hexagon socket head bolt -M8 x 15- C -  Puller, e.g. -Kukko 18/1- –  Pull off synchro-hub for 5th and 6th gears with inner race for 6th gear needle bearing and 5th gear synchro-ring.   Note The synchro-ring for 5th gear must always be renewed after it is pulled off. –  Remove flange shaft securing bolt by screwing 2 bolts into flange and counterholding flange shaft with a lever.

–  Pull out flange shaft -1- with spring. –  Remove sleeve -2- and 5th gear synchromeshed gear with needle bearing -4-. –  Unscrew hexagon flange nut -5- for securing reverse gear selector mechanism. –  Remove bearing mounting securing bolts -6- from input and output shafts. 5th gear wheel can be removed by hand. –  Remove gear wheel for 5th gear -3-. 5th gear wheel cannot be removed by hand. –  The gear wheel for 5th gear -3- will be pressed off later when the bearing support for the deep groove ball bearing → Fig.. Continuation for all –  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.

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

–  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. –  Screw out reversing light switch -F4--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. 5th gear wheel cannot be removed.

–  Press out input shaft, output shaft with gear wheel for 5th gear -A-, 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. 5th gear wheel can be removed.

–  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. Continuation for all –  Press input and output shafts, together with gear wheel for 5th gear, off deep groove ball bearing → Fig.. –  Press input and output shafts, without gear wheel for 5th gear, off bearing mounting with deep groove ball bearing → Fig..