Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling gearbox housing

1 -	Gearbox housing

q	With oil guide → Fig.

2 -	Baffle plate

q	Smooth side faces outwards

3 -	Differential shim

q	Determining thickness → Chapter.

4 -	Differential bearing race

q	Driving out → Fig.

q	Driving in → Fig.

5 -	Output shaft shim 3

q	Determining thickness → Chapter.

6 -	Output shaft bearing race 3

q	Pulling out → Fig.

q	Preparing for pressing in → Fig.

q	Pressing in → Fig.

7 -	Output shaft shim 2

q	Determining thickness → Chapter.

8 -	Output shaft bearing race 2

q	Pulling out → Fig.

q	Preparing for pressing in → Fig.

q	Pressing in → Fig.

9 -	Output shaft shim 1

q	Determining thickness → Chapter.

10 -	Output shaft bearing race 1

q	Pulling out → Fig.

q	Pressing in → Fig.

11 -	Bearing for the inner input shaft

q	Remove to press out retaining ring

q	Press in »new« bearing → Fig.

12 -	Retaining ring

q	Always renew

Press in bearing for inner input shaft –  Press in bearing bearing to stop. –  Install »new« retaining ring.

Installation position of oil guide in gearbox housing –  Oil guide is clipped into housing.

Pull out bearing races of output shafts All bearing races of output shafts 1 to 3 are removed »in the same way«. Here, for example, the removal of output shaft 1 is described. Bearing races of output shafts 2 and 3 are removed in the same manner. –  Make sure that bearing race does not »get stuck« on supports of puller.

Pressing in bearing race of output shaft 1 –  Insert shim. –  Press in bearing race to stop.

Prepare bearing races of output shafts 2 and 3 for pressing in –  First insert 1 shim into housing. –  Then position »correct« bearing race and drive bearing race in using targeted, light taps until it can no longer drop out.

–  Fit spacer sleeve -T10428- and press tool -VW 402- onto press.

Pressing in bearing races of output shafts 2 and 3 This shows how bearings of output shaft 2 are pressed in. -A- Output shaft bearing race 2 -B- Output shaft bearing race 3 –  To press in bearing of output shaft 2, place housing on thrust piece -B-.

Driving out bearing race of differential Bearing is driven out using a suitable drift. –  Before driving out, place ring of thrust pieces for drive pinion bearing -VW 470- under bearing. –  To prevent gearbox housing from rocking, also insert wedge -T10357- under housing.

Drive in bearing race of differential A second mechanic is required for driving in. –  Place thrust piece -T10380- on edge of workbench. Position gearbox housing with area of bearing point on thrust piece, and hold housing firmly like that. –  Second mechanic inserts oil ring and shim. 2. Mechanic drive bearing in as far as stop.