Volkswagen Workshop Service and Repair Manuals

Procedure for removing and installing gearbox housing cover, gearbox housing, selector mechanism, input shaft, output shaft, differential and selector forks

Special tools and workshop equipment required

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Drift -VW 295-

t	Drift sleeve -VW 244 B-

t	Hot air blower -V.A.G 1416-

t	Torque wrench -V.A.G 1331-

t  Socket -V.A.G 1669-

t  Two-arm puller -1 - Kukko 20/10- with Matra V170 pulling hook t  Studs M8 x 100 mm t  Hexagon bolt M10 x 20 Removing –  Drain gear oil from gearbox and bevel box. –  If a cap is fitted, remove it by piercing cap centre with a screwdriver and levering out.

–  Remove right output shaft bolt or right flange shaft bolt using socket -V.A.G 1669- or commercially available 6 mm socket.   Note Right flange shaft or drive flange with output shaft remains in bevel box. –  Remove four bevel box/gearbox connecting bolts -arrow A- and -arrow B-. –  Press bevel box off gearbox.

–  Bolt gearbox to repair stand. –  Remove clutch release lever and release bearing → Chapter. –  Unbolt guide sleeve → Chapter.

–  Remove gearbox housing cover -arrow-.

–  Remove 5th gear selector fork -arrow-   Note Before lifting the locking collar, take off spring and lock body. Then afterwards replace locking collar on synchro-hub again, but without selector fork.

–  Remove bolts -A- for synchro-hub and 5th gear, to do this select 1st gear -arrows 2 and 3- and 5th gear -arrow 1-. –  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. –  Pull off synchro-hub with 5th gear wheel and take off needle roller bearing.

-A-Two-arm puller -Kukko 20/10- with hooks -Matra V/170.- -B- Hexagon head bolt M10×20 –  Pull off gear wheel for 5th gear.

-A-Two-arm puller -Kukko 20/10- with hooks -Matra V/170.- -B- Hexagon head bolt M10×20 Removal sequence: –  Assemble two arm puller and centre by turning screw -arrow-. –  Pull gear wheel off using two arm puller, first heating with hot air blower -V.A.G 1416- if necessary.   Note When pulling off gear wheel, ensure that hooks do not bend outwards, further tightening bolt -arrow- if necessary. After pulling off gear wheel for 5th gear, examine for damage.

–  Remove left-hand flange shaft by removing countersunk bolt -arrow-.

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

–  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 gearbox housing, if necessary carefully levering up all around along protruding housing flange and alternating between sides -arrows-, being careful not to damage sealing surfaces.

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

–  Remove nuts for output shaft bearing support.

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

–  Always renew sealing rings -arrows- for output shaft bearing support.   Note The figure shows only 3 of the 4 sealing rings. –  Remove differential. Installing –  Install input shaft, output shaft and reverse shaft together. –  Tighten nuts for output shaft bearing support to specified torque → Item.

–  Clean residual locking fluid from threads in reverse shaft support -arrow-. Threads can be cleaned using a thread chaser. –  Install reverse shaft support. –  Install reverse gear selector mechanism.

Installation position, reverse gear –  Install selector forks together with selector plates.

–  Screw M8 x 100 mm studs -A- into reverse shaft support so that shaft is aligned after gearbox housing is fitted. –  Align selector plates.   Note The selector segments must be positioned in the grooves on the locking collars. –  Fit gearbox housing. Install reverse shaft support bolts -arrow- as follows:

–  Install bolt -a-.

–  Remove stud -A-.

–  Install bolt -b- and tighten by hand. Tightening sequence: 1. - Bolt -a- 30 Nm 2. - Bolt -b- 30 Nm

–  Install pivot pin -arrow- for selector forks. Do this by aligning selector mechanism with a screwdriver so that respective pivot pin can be installed. –  Fit selector shaft cover.

Install selector shaft as follows: –  Place selector plates in neutral. –  Locate lug -arrow 1- in recess in gearbox housing. Position selector shaft so that selector finger -arrow 2- is inserted in the selector plates. –  Install selector shaft cover.

Installation position, 5th gear wheel The circumferential groove -arrow- faces gearbox housing.

–  Drive on gear wheel for 5th gear. Check 5th gear synchro-ring.

–  Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap -a- with a feeler gauge.

Gap -a-	Installation (new) dimension	Wear limit
5th gear	1,1 ... 1.7 mm	0.5 mm

–  Install 5th gear synchromeshed gear with needle bearing. –  Place 5th gear synchro-ring on synchromeshed gear. –  Assemble 5th gear synchro-hub and locking collar before installing → Fig..

Installation position 5th gear synchro-hub and locking collar The pointed teeth of the locking collar -arrow 1- and the high shoulder of the synchro-hub -arrow 2- face the gearbox housing. The synchro-hub mountings -arrow 3- align with the 5th gear synchro-ring cast locking pieces.

5th gear synchro-ring with cast locking pieces -arrows-

–  Drive on 5th gear synchro-hub.   Note When driving on, ensure that synchro-ring moves freely. –  Screw in securing bolts for synchro-hub and gear wheel for 5th gear.

Installation position of dished springs for securing bolts for gear wheel and synchro-hub for 5th gear The outer diameter (concave side -arrows-) faces 5th gear. –  Engage two gears before tightening securing bolts for 5th gear synchro-hub and gear wheel.

–  To do this, engage 1st gear -arrow 2- and -arrow 3- and 5th gear -arrow 1-.

–  Tighten securing bolts for synchro-hub and gear wheel for 5th gear -arrows- to specified torque → Item. –  Install 5th gear selector fork.

Adjusting 5th gear –  Engage 5th gear. Loosen bolt -1-. Push locking collar and selector jaw in direction of arrow and then tighten bolt -1- to 25 Nm. l  Check measurement: It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary, repeat adjustment. –  Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely. –  Mount gearbox housing cover. –  Install complete left flange shaft → Item. –  Install release bearing guide sleeve → Chapter. –  Install clutch release lever and release bearing → Chapter. Install bevel box as follows:

–  Always renew O-ring for sealing bevel box and gearbox -arrow A- and oil seals for sealing sleeves for oil supply system -arrows B and C-, lightly coating with oil. –  Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft are guided centrally onto differential connecting piece. –  Also bring splines of right flange shaft or drive flange with output shaft into alignment. –  If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox. –  Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.

–  Tighten bevel box/gearbox connecting bolts -arrows A- and -B- to specified torque → Anchor. –  Tighten flange shaft countersunk bolt or drive flange with output shaft with socket -V.A.G 1669- or commercially available 6 mm socket insert to specified torque → Item and hold against turning with drift.