Volkswagen Workshop Service and Repair Manuals

Removing

Gearbox for vehicles with 5 and 6-cylinder engines –  Secure gearbox to assembly stand using bolts -arrows-.

Gearbox for vehicles with 4-cylinder engine –  Secure gearbox to assembly stand using bolts -arrows-. Continued for all gearboxes –  Rotate gearbox on assembly stand so that oil drain plug is below. –  Place drip tray underneath. –  Drain gear oil from gearbox and bevel box.

–  Remove right flange shaft bolt using socket -V.A.G 1669- or commercially available 6 mm socket.   Note Right flange shaft remains in bevel box. –  Remove four bevel box/gearbox connecting bolts (only three shown in figure) -arrows-. –  Press bevel box off gearbox.

–  Remove slave cylinder with clutch release bearing -arrows-. –  Move selector shaft to neutral.

–  Remove reversing light switch -1-. –  Remove hexagon bolts -2- for selector shaft cover plate -A-. –  Carefully pull out cover plate. –  Remove locking bolt -3- for selector shaft guide. –  Then remove bolts -4- and press selector mechanism cover -B- out of gearbox housing. –  Pull selector shaft out of gearbox housing. –  Remove left flange shaft.

–  Remove securing bolts -A- for gearbox housing to clutch housing in area of differential.

–  Remove bolts -B-, which serve to secure gearbox housing to clutch housing.   Note Hexagon bolt -arrow- is located outside of bolting flange. It is installed with a washer. –  Remove gearbox housing; if necessary carefully apply lever at overhanging housing shoulders along perimeter alternately using assembly lever, being careful not to damage sealing surfaces.

From gearbox date 06 04 0 –  Unscrew locking plate bolt -arrow- (tapered roller bearing outer race for input shaft). –  Remove locking plate. Continued for all gearboxes

–  Swing input shaft in direction of arrow and remove. –  Remove speedometer sender.

–  With the help of a second mechanic, remove differential -1-, output shafts -2- and -3-, reverse shaft -4- and selector rods -5- together from clutch housing. –  Drive out input shaft oil seal using sleeve -30-21-.