Volkswagen Workshop Service and Repair Manuals

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

• ◆ VW 408 A Press tool
• ◆ VW 472/2 Spacer sleeve
• ◆ 12-551 Centring mandrel
• ◆ 30-555 Thrust piece
• ◆ 3066 Spindle from assembly tool
• ◆ 3124 Press piece

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

• ◆ 3221 Gearbox bracket (modifying )
• ◆ T40008 Press piece
• ◆ V.A.G 1331 Torque wrench
• ◆ 2 - Kukko 18/1 Puller
• ◆ 3 - Kukko 17/1 Separating device

• Clutch housing
• ◆ If replaced: Adjust differential
  => page 39-23
• Input shaft oil seal
• ◆ Lever out with screwdriver
• ◆ Driving in => Fig.1
• Ball stud, 20 Nm
• ◆ Lubricate with MoS2 grease
• Oil seal for flanged shaft, right
• ◆ Renewing with gearbox installed => page 39-5
• Sleeve
• ◆ For oil seal
• ◆ Pulling out => Fig.2
• ◆ Pressing in => Fig.3

• Bolt, 40 Nm and turn 45° further
• ◆ Qty. 4
• ◆ Always renew
• Bracket
• ◆ For pendulum support
• ◆ Installation position => from page 34-37
• Oil filler plug, 25 Nm
• O-ring
• ◆ Always renew
• Speedometer sender -G22-
• Bolt, 5 Nm and turn 90° further
• ◆ Always renew
• Shim S2
• ◆ For differential
• ◆ Determining thickness => page 39-23

• Outer race/taper roller bearing
• ◆ For differential
• ◆ Pulling out and pressing in
  => Page 39-8
• ◆ If replaced: Adjust differential
  => page 39-23
• Bolt, 5 Nm and turn 90° further
• ◆ Always renew
• Outer race/taper roller bearing
• ◆ For differential
• ◆ Pulling out and pressing in
  => Page 39-8
• ◆ If replaced: Adjust differential
  => page 39-23
• Shim S1
• ◆ For differential
• ◆ Always 1 mm thick
• Dowel sleeve
• ◆ Qty. 2

• Gearbox housing
• ◆ If replaced: Adjust differential
  => page 39-23
• Oil drain plug
• ◆ => page 34-55 , item 3
• Oil seal for flanged shaft, left
• ◆ Renewing with gearbox installed => page 39-1
• Sleeve
• ◆ For selector shaft
• ◆ Driving out => Fig.4
• ◆ Driving in => Fig.5
• Magnet
• ◆ Held in place by housing joint surface
• Sealing cap
• ◆ Apply AMV 188 200 03 to sealing surface before bolting on

• Circlip
• ◆ Fit in groove of roller bearing -item 27 -
• Circlip
• ◆ Fit in groove of roller bearing -item 26 -
• Roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-1
• Roller bearing
• ◆ For output shaft
• ◆ Removing and installing
  => Page 35-20

→ Fig.1     Driving in input shaft oil seal flush

→ Fig.2     Pulling out oil seal sleeve

• ‒ Fit spacer sleeve VW 472/2 and thrust piece 30-555 on differential.

A - Puller, e.g. Kukko 18/1

B - Separating device 12...75 mm, e.g. Kukko 17/1

→ Fig.3     Pulling oil seal 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.4     Driving out selector shaft sleeve -A-

→ Fig.5     Driving in selector shaft sleeve -A-