Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ VW 295 Drift
• ◆ VW 295a Adapter
• ◆ VW 447 H Press plate
• ◆ VW 512 Press disk
• ◆ VW 415 A Tube
• ◆ VW 454 Press piece

Special tools and workshop equipment required

• ◆ VW 228 B Puller
• ◆ VW 222 A Drift
• ◆ 3066 Spindle from assembly tool
• ◆ 3124 Press piece
• ◆ V.A.G 1331 Torque wrench

• Gearbox housing
• ◆ If replaced: Adjust input shaft and differential
• Needle roller bearing
• ◆ For output shaft
• ◆ Removing => Fig.1
• ◆ Installing and securing
  => Fig.2
• Oil filler plug, 25 Nm
• ◆ Without magnet
• Shim
• ◆ For input shaft
• ◆ Adjustment overview
  => Page 39-22
• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-8
• ◆ If replaced: Adjust input shaft
  => Page 35-15

• Outer race/taper roller bearing
• ◆ For output shaft
• ◆ Removing and installing
  => Page 35-36
• ◆ If replaced: Adjust output shaft
  => Page 35-54
• Shim
• ◆ For output shaft
• ◆ Adjustment overview
  => Page 39-22
• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-12
• ◆ If replaced: Adjust input shaft
  => Page 35-15
• Needle bearing
• ◆ Removing and installing
  => Page 35-63

• Dowel sleeve
• ◆ (Qty. 2)
• Starter bush
• ◆ Pulling out => Fig.5
• ◆ Knocking in => Fig.6
• ◆ Can be replaced without removing gearbox
• Clutch housing
• ◆ If replaced: =>Adjustment overview, Page 39-22
• Guide sleeve
• ◆ With input shaft seal and a vulcanised O ring
• ◆ Knocking-out oil seal => Fig.3
• ◆ Knocking-in oil seal => Fig.4
• ◆ Remove guide sleeve to change the oil seal
• ◆ If damaged replace guide sleeve and O-ring together

• Socket head bolt, 20 Nm
• ◆ Self-locking
• ◆ Always renew
• Oil seal
• ◆ Renewing => Page 39-1
• Sleeve
• ◆ For oil seal (Item 15 )
• ◆ Removing => Fig.7
• ◆ Installing => Fig.8
• Speedometer drive, 30 Nm
• Oil drain plug, 25 Nm
• ◆ Without magnet
• Outer race/taper roller bearing
• ◆ For differential
• ◆ Removing and installing
  => from Page 39-5
• ◆ If replaced: Adjust differential
  => page 39-23

• Magnet
• ◆ Held in place by housing joint surface
• Outer race/taper roller bearing
• ◆ For differential
• ◆ Driving in and out
  => Page 39-5
• ◆ If replaced: Adjust differential
  => page 39-23
• Shim
• ◆ For differential
• ◆ Adjustment overview
  => Page 39-22
• Oil seal
• ◆ Renewing => Page 39-1

→ Fig.1     Knocking-out needle roller bearing.

→ Fig.2     Knocking needle roller bearing in onto stop

• ‒ Secure needle roller bearing in gearbox housing at three points (120° offset) with a punch.

→ Fig.3     Knocking oil seal out of guide sleeve.

→ Fig.4     Knock oil seal into the guide sleeve onto stop.

→ Fig.5     Pulling out starter bush.

→ Fig.6     Knocking in starter bush.

→ Fig.7     Lever out sleeve with screwdriver

→ Fig.8     Pulling sleeve in

• ‒ Pull sleeve in onto stop with thrust piece 3124 by turning on nut -B-.

Note:

When gearbox is dismantled press sleeve in with thrust piece 3124 onto stop.