Volkswagen Workshop Service and Repair Manuals

Repairing gearbox housing and selector shaft

Special tools and workshop equipment required

t	Setting gauge -VW 521-

t	Fitting tool -3128-

t	Press tool -40-503-

t	Press tool -30-505-

t	Drift -VW 295-

t	Adapter -VW 295 A-

t  Spindle from assembly tool -3291-

1 -	Gearbox housing

q	If renewed, adjust differential → Chapter

q	From gearbox date 03 08 8, with additional threaded hole for reversing light switch → Fig..

2 -	Dowel sleeve

q

(Qty. 2)

3 -

Sleeve

q	Remove with pliers.

q	Drive in to stop.

4 -

Cap

q	For gearbox breather

5 -	Reversing light switch and selector shaft locking bolt, 20 Nm

q	From gearbox date 03 08 8, reversing light switch and locking bolt are separate components → Fig..

6 -	Selector shaft

q	Removing → Fig..

7 -

Stop cap

8 -	Compression spring

9 -	Retaining plate

q	Hold retaining plate tight when releasing retaining ring → Item. Carefully release tension on compression spring → Item.

10 -	Retaining ring

q	Always renew

11 -	Needle bearing

q	For output shaft

q	Removing → Fig..

q	Installing → Fig.

12 -	Ball sleeve

q	For selector shaft

q	Pulling out → Fig.

q	Pulling in → Fig.

13 -

Seal

q	For selector shaft

q	Can be renewed with gearbox installed.

q	Removing → Fig..

q	Pulling in → Fig.

14 -	Tapered roller bearing outer race

q	For differential

q	Driving in and out → Chapter.

q	If renewed, adjust differential → Chapter

15 -	Flange shaft oil seal

q	Renewing → Chapter

Removing selector shaft –  Unscrew selector shaft sealing cover and remove together with compression spring. –  Move selector shaft to neutral position and pull out of gearbox housing.

Removing selector shaft seal -A- –  Lever out in -direction of arrow- with a screwdriver.

Pulling in selector shaft seal –  Pull in to stop. –  Drive in with -VW 521/8- when gearbox is removed.

Pulling out selector shaft ball sleeve A -  Internal puller, 18.5 … 23.5 mm, e.g. -Kukko 21/3- B -  Counter support, e.g. -Kukko 22/1-

Pulling in selector shaft ball sleeve –  Pull in to stop -arrow 1-. Installation position: The ball sleeve projects out of hole at seal end -arrow 2-.

Driving out needle roller bearing

Driving needle bearing in to stop