volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Front-wheel drive - repairing clutch housing > < Installing
Repairing gearbox housing
   
Repairing gearbox housing
Special tools and workshop equipment required
t  Drift sleeve -VW 244B-
t  Gearbox support -VW 353-
t  Pressure plate -VW 401-
t  Pressure plate -VW 402-
t  Press tool -VW 407-
t  Tube -VW 416 B-

   
t  Guide pin -VW 436 A-
t  Guide pin -VW 439-
t  Multipurpose tool -VW 771-
t  Support plate -VW 801-
t  Guide pin -10-15-
t  Thrust piece -3124-

   
t  Drift -3264-
t  Assembly tool -3290-
t  Torque wrench -V.A.G 1331-
t  Drift -T10168-
t  Thrust piece -T10203-
t  Drift -T10169-
t  or drift -T10362- → Fig.

  W00-10523
t  -1-Internal puller -Kukko 21/2-
t  -1-Internal puller -Kukko 21/4-
t  -4-Counter support -Kukko 22/2-
t  Thread adapter from counter support -Kukko 22/1-
  W00-0633
1 - Gearbox housing
q   If renewed: adjust output shafts and differential → Chapter
q   Changes in area of support for deep groove ball bearing for input shaft → Item.
q   Changes in area of support for input shaft cover → Item
q   Allocation of components via → Electronic parts catalogue (ETKA)
2 - Cover plate
q   Removing → Fig.
q   Driving in → Fig.
3 - Oil drain plug
q   Torque setting → Fig.
4 - Seal
q   Always renew, if part of original equipment
5 - Oil filler plug
q   Torque setting → Fig.
6 - Angled rod
q   For adjusting selector mechanism → Chapter
q   Can be renewed with gearbox assembled
q   Removing → Fig.
q   Installation position → Fig.
q   Driving in → Fig.
7 - Bearing bush
q   For selector rods
q   Pulling out → Fig.
q   Driving in → Fig.
8 - Stop sleeve
q   Pressing out with gearbox dismantled → Fig.
q   Pressing out with gearbox assembled → Fig.
q   Stop sleeve identification → Fig.
q   Drive in stop sleeve with shoulder → Fig.
q   Drive in stop sleeve without shoulder → Fig.
9 - Needle bearing
q   For reverse shaft
q   Renew each time after removing
q   Pulling out → Fig.
q   Pressing in → Fig.
10 - Tapered roller bearing outer race
q   For output shaft for 5th, 6th and reverse gears
q   Removing and installing → Chapter
q   If renewed, adjust output shaft for 5th, 6th and reverse gears → Chapter
11 - Shim
q   For output shaft for 5th, 6th and reverse gears
q   Adjustment overview → Chapter
12 - Tapered roller bearing outer race
q   For output shaft for 1st through 4th gears
q   Removing and installing → Chapter
q   If renewed, adjust output shaft for 1st through 4th gears → Chapter
13 - Shim
q   For output shaft for 1st through 4th gears
q   Adjustment overview → Chapter
14 - Tapered roller bearing outer race
q   For differential
q   Front-wheel drive, removing and installing → Chapter
q   Four-wheel drive, removing and installing → Chapter
q   If renewed, adjust differential → Chapter
15 - Shim
q   For differential
q   Adjustment overview → Chapter
16 - Bearing bush
q   For selector shaft
q   Pulling out → Fig.
q   Driving in → Fig.
17 - Plug
q   Driving out → Fig.
q   Driving in → Fig.
18 - Seal
q   Front-wheel drive - renewing → Chapter
q   Four-wheel drive - renewing → Chapter

   
Removing sealing cover -A-
–  Pierce centre of sealing cover using screwdriver -B- and lever out cover -in direction of arrow-.
  N34-10039
Driving in sealing cover to stop
  N34-10040
Removing angled rod for selector shaft
–  Break off angled rod in released position.
–  Insert a screwdriver -A- in hole for angled rod -B-.
–  Lever out angled rod in -direction of arrow-.
  N34-10042
Installation position of angled rod
–  Marking on angled rod -arrow- must face slave cylinder connection -1-.
Dimension -a- must be about 45°.
  N34-10043
Drive in angled rod for selector shaft -arrow- to stop of tool.
  Note
Angled rod must be released while it is being driven in.
  N34-10044
Pulling out selector rod bearing bush
A - Internal puller, 14.5 … 18.5 mm, e.g. -Kukko 21/2-
B - Counter support, e.g. -Kukko 22/2-
  N34-1576
Driving in selector shaft bearing bush to stop of tool
  N34-10309
Pressing stop sleeve -A- out of gearbox housing
–  Set gearbox housing on thrust plates -VW 401- and -VW 402- so that dowel sleeves in gearbox housing are not damaged.
  N34-10046
Driving stop sleeve out of assembled gearbox using guide pin -10-15-
l  Remove locking screw and selector shaft.
–  Turn gearbox so that stop sleeve does not fall in gearbox.
  N34-10047
Stop sleeve identification
Following stop sleeves can be installed:
Stop sleeve with shoulder -arrow 1- → Fig..
Stop sleeve without shoulder -arrow 2- → Fig..
Allocate components according to → Electronic parts catalogue „ETKA“.
  N34-10855
Drive in stop sleeve with shoulder until tool makes contact
l  Clutch housing bolted to gearbox housing.
  N34-10308
Drive in stop sleeve without shoulder until tool makes contact
l  Clutch housing bolted to gearbox housing.
  N34-10861
Pulling reverse shaft needle bearing out of gearbox housing
A - Internal puller, 23.5 … 30 mm, e.g. -Kukko 21/4-
B - Counter support, e.g. -Kukko 22/2-
  Note
The needle bearing is destroyed during removal and must be renewed.
  N34-1578
Pressing needle bearing -A- into gearbox housing
–  Before pressing in, lay reverse shaft thrust washer -B- on needle bearing.
–  Support gearbox housing with tube -VW 416 B- directly below bearing support.
  N34-1010
Pulling out selector shaft bearing bush
–  Use thread adapter from counter support -Kukko 22/1--arrow-.
–  Hold spindle of assembly tool -3290- securely and turn nut -B-.
A - Internal puller, 14.5 … 18.5 mm, e.g. -Kukko 21/2-
  N34-10970
Driving in selector shaft bearing bush -A- to stop of tool.
  N34-10310
Driving out plug -1-
–  Drive plug -1- outwards -arrow- from inside gearbox housing.
  N34-10050
Driving in plug -1-
–  Drive in sealing plug to dimension -a-, approx. 3 mm below upper edge of housing, using drift -3264-.
  N34-10051

Front-wheel drive - repairing clutch housing > < Installing