Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items 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, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ VW 228 B Puller
• ◆ VW 222 A Drift
• ◆ 3066 Spindle from assembly tool

Oil seal and sleeve are two parts:

• ◆ 3124 Press piece

Oil seal and sleeve are one part:

• ◆ VW 771 Multi-purpose tool
• ◆ VW771/37 Puller hooks

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

Oil seal and sleeve are one part:

• ◆ T10148 Thrust piece

• 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, 30 Nm
• ◆ Without magnet
• Shim
• ◆ For input shaft
• ◆ Adjustment overview
  => Page 39-27
• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-8
• ◆ If replaced: Adjust input shaft
  => Page 35-17

• Outer race/taper roller bearing
• ◆ For output shaft
• ◆ Removing and installing
  => Page 35-38
• ◆ If replaced: Adjust output shaft
  => Page 35-56
• Shim
• ◆ For output shaft
• ◆ Adjustment overview
  => Page 39-27
• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-13
• ◆ If replaced: Adjust input shaft
  => Page 35-17
• Needle bearing
• ◆ Removing and installing
  => Page 35-63

• Dowel sleeve
• ◆ (Qty. 2)
• Starter bush
• ◆ Not featured on all gearboxes
• ◆ Allocate using parts catalogue
• ◆ Pulling out => Fig.5
• ◆ Knocking in => Fig.6
• ◆ Can be replaced without removing gearbox
• Clutch housing
• ◆ If replaced: =>Adjustment overview, Page 39-27
• Guide sleeve
• ◆ With input shaft seal and a vulcanised or bonded O-ring
• ◆ Knocking-out oil seal => Fig.3
• ◆ Knocking-in oil seal => Fig.4
• ◆ Remove guide sleeve to change the oil seal
• ◆ If damaged or loose, replace guide sleeve and O-ring together

• Socket head bolt, 20 Nm
• ◆ Self-locking
• ◆ Always renew
• Oil seal
• ◆ Renewing with gearbox installed => page 39-1
• Sleeve
• ◆ For oil seal (Item 15 )
• ◆ Removing => Fig.7
• ◆ Installing => Fig.8
• Oil seal and sleeve one part
• ◆ If damaged replace oil sleeve and oil seal together
• ◆ Removing => Fig.9
• ◆ Installing => Fig.10

• Speedometer drive
• ◆ Aluminium type, tighten to 30 Nm
• ◆ Plastic type (polyamide), tighten to 10 Nm
• Oil drain plug, 30 Nm
• ◆ Without magnet
• Outer race/taper roller bearing
• ◆ For differential
• ◆ Removing and installing
  => from Page 39-10
• ◆ If replaced: Adjust differential
  => page 39-28
• Magnet
• ◆ Held in place by housing joint surface

• Outer race/taper roller bearing
• ◆ For differential
• ◆ Driving in and out
  => Page 39-10
• ◆ If replaced: Adjust differential
  => page 39-28
• Shim
• ◆ For differential
• ◆ Adjustment overview
  => Page 39-27
• Oil seal
• ◆ Renewing with gearbox installed => 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.

Sequence for assembling puller VW 228 b

• ‒ Turn nut on thread of puller until stop in direction of tensioning bolt.
• ‒ Insert puller VW 228 b in onto limit stop.
• ‒ Now tighten tensioning nut until puller VW 228 b is tensioned on 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.

→ Fig.9     Pull out sleeve and oil seal

A shoulder is located on the internal diameter of the sleeve

• ‒ When pulling seal and sleeve out, seat puller hooks of VW 771/37 behind shoulder in sleeve.
• ‒ When pulling out press puller hooks of VW 771/37 into sleeve with force.

→ Fig.10     Pulling sleeve and seal in

• ‒ Clean oil seal seat in gearbox.

• ‒ Pull sleeve in over thrust piece T10148 onto stop by turning on nut -B-.

Note:

When gearbox is dismantled press sleeve in onto stop with thrust piece T10148.