Dismantling gearbox

Make

Volkswagen

Model

Golf Mk5

Section

7-speed dual clutch gearbox 0AM › Gearbox,mechanics,gears,shafts,internal operation › Dismantling gearbox

Power transmissionDismantling gearbox

Dismantling gearbox –  Secure gearbox to stand → Chapter. Prerequisites l  Clutch is removed l  Mechatronic unit is removed l  Gear oil is drained

–  Engage parking lock.

–  Remove cable support bracket.

–  Remove lever and cover.

–  Remove parking lock → Chapter. –  Remove dual clutch → Chapter.

–  If not already removed: remove both engaging levers. –  Remove mechatronic unit → Chapter. –  Remove flange shafts or stub shafts → Chapter.

–  Remove connecting bolts of housing halves at clutch end.

–  Fit support bridge -T10323- and rotate spindle against inner input shaft until finger tight. This supports shaft. Gearbox housing is pulled off later. In this way, the force required is not applied to the gearbox in an uncontrolled manner.

–  Turn gearbox, remove remaining connecting bolts of housing halves.

–  Penetrate cover of „inner input shaft“ and lever out. Drive screwdriver »centrally« and at a very »acute« angle into cover. Only far enough so you can lever out cover.

–  Remove retaining ring. –  Remove dowel sleeves of mechatronic unit.

–  From above, mount another puller. Screw on -A-square pin -T10427/1- and -B-angled rod -T10427- until finger-tight. Spindle should press against input shaft. –  Whilst pulling off, you can apply »targeted« hammer blows to reinforce pulling force. –  Use a hardwood block as protection. This will make it easier to release glue between both housing halves. –  Pull off gearbox housing and place it to one side.

Gearbox housing can be clamped in 1 vice for further assembly with puller.

–  Remove magnet and clean it.

–  Move selector fork for 1st and 3rd gear upwards into 1st gear. –  Slightly raise output shaft 1, tip it is a little -arrow- and remove selector fork.

–  Move selector fork for 2nd and 4th gear upwards into 4th gear. –  In this case too, raise output shaft 1 slightly, tilt it and remove selector fork.

–  Remove output shaft 1.

–  Shift down both remaining selector forks.

–  Raise output shafts 2 and 3 out of the lower bearings.

–  Place both shafts »in direction of« selector forks onto clutch housing.

–  Screw one guide pin -3411- into differential. –  Remove differential. Output shaft 2 can be raised slightly for this purpose.

–  Remove output shafts 2 and 3.

–  Selector forks rotate »inwards«. –  Remove selector forks.

–  Remove inner input shaft. –  There is a roller bearing between inner and outer input shaft. Please also remove this. l  This bearing is not allowed to be broken.

–  Unscrew 3 bolts. –  Turn over clutch housing together with »last«, outer input shaft.

–  Lever out outer oil seal.

–  Outer input shaft can be pressed out now. –  Hold shaft firmly with one hand. This prevents it from falling down.   Note

»Pressed out« shaft will fall down. –  Bearing of outer input shaft must always be renewed → Chapter. New retaining ring -arrow- must also be pressed in. Pressing out shaft caused force to be applied through balls of bearing. –  Clean surfaces of both housings with silicone remover -LSE020100A3-. Disassembly of gearbox is completed. Further »links«: Assembling gearbox → Chapter. Dismantling and assembling gearbox housing → Chapter Dismantling and assembling clutch housing → Chapter Dismantling and assembling outer input shaft → Chapter Dismantling and assembling inner input shaft → Chapter. Dismantling and assembling output shaft 1 → Chapter. Dismantling and assembling output shaft 2 → Chapter. Dismantling and assembling output shaft 3 → Chapter.

04 Transmission

The same page in: Golf Mk6.