Volkswagen Workshop Service and Repair Manuals

Removing –  Remove clutch release lever, release bearing and guide sleeve → Chapter. l  Bearings of input shaft and output shaft must not be damaged when 5th and 6th gears are removed and installed.

l  Therefore, following tools must be mounted for support at this stage during attachment of gearbox to gearbox support -VW 353-: The illustration shows a gearbox for front-wheel drive. Underneath input shaft: t  Support bridge -30-211A- t  Thrust piece -32 - 111- t  Thrust piece -T10030/4- –  Lock bolt of support bridge -30-211A- with nut -A-. Underneath bearing support for output shaft: t  Support device -T10323- t  Assembly tool -3253/7- t  Thrust piece -VW 433-

–  Secure gearbox on gearbox support -VW 353- Remove bevel box:

–  Remove right flange shaft countersunk bolt with socket -T10107 A-. –  Remove the 4 connecting bolts -arrows- for bevel box to gearbox (only 3 are visible in figure). –  Carefully press bevel box off gearbox, taking care that it does not fall. –  Place drip tray -V.A.G 1306- underneath. –  Remove oil filler plug and oil drain plug. –  Drain gear oil.

–  Remove gearbox housing cover -arrow-. –  Remove cover, if necessary carefully levering up all around along protruding housing flange and alternating between sides, being careful not to damage sealing surfaces.

–  Remove selector fork for 5th and 6th gears as follows: –  Cover openings with a cloth. –  Engage 5th gear -arrows 1- and -2-. –  Remove selector jaw for 5th and 6th gears -bolt A-. –  Then remove both bolts -B- for pivot pins. –  Pull out pivot pins. –  Remove selector fork for 5th and 6th gears.

–  Remove -bolts A- for inner bearing races from input and output shafts, engaging 5th gear -arrow 1- and 1st gear -arrow 2- and -arrow 3-. –  Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened.   Note If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.

–  Remove both bolts -arrows- for reverse shaft support bracket.

–  Now remove 3rd bolt -arrow- for reverse shaft support bracket.

–  Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position. Then remove bolts -arrows- and pull selector shaft out of gearbox housing.

–  Remove cover plate -A- and pivot pins -B- from underside of gearbox.

–  Remove pivot pins -A- on top side of gearbox and securing bolts -B- for gearbox housing to clutch housing in area of differential.

–  Remove bolts -A- from clutch housing side for securing clutch housing to gearbox housing.   Note Do not remove nuts -B- for output shaft bearing support.

–  Remove left flange shaft. –  Remove flange shafts together with springs, thrust washers and tapered rings.

Pull off following components together with gearbox housing: t  Synchro-hub for 5th/6th gears t  Gear wheel for 6th gear t  Gear wheel for 5th gear l  Both grips -T10408/3- must be secured on gear wheel for 5th gear. l  The grips must always be positioned above the two housing ribs, which are located opposite each other -arrows-.   Note t  There is a needle bearing beneath the gear wheel for 5th gear. t  Secure the grips so that the bearing does not come in contact with the gear wheel for 5th gear when the gearbox housing is pulled off.

Use puller plate -T10408- in conjunction with following special tools: t  Thrust pieces -T10408/2- t  Grips -T10408/3- t  Puller Kukko 18/1 –  Screw puller plate -T10408- firmly into threaded holes for gearbox housing cover. A -  Hexagon bolts M7 x 35 with washers Torque setting 18 Nm –  Place thrust pieces -T10408/2- on shafts.

–  Install pullers Kukko 18/1-A-. –  Pull off 5th and 6th gear synchro-hub, gear wheel for 6th gear, gear wheel for 5th gear and gearbox housing by alternately tightening spindles -A- approx. 1 2 turn. –  Heat 5th and 6th gear wheels slightly with hot air blower -V.A.G 1416- if necessary.

–  Remove selector forks -A- together with selector plates. –  Unbolt reverse gear selector mechanism -B-.

–  Remove nuts -B- for output shaft bearing support.

–  Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing. –  Remove differential.