Volkswagen Workshop Service and Repair Manuals

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.

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-

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-.

Driving in sealing cover to stop

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-.

Installation position of angled rod –  Marking on angled rod -arrow- must face slave cylinder connection -1-. Dimension -a- must be about 45°.

Drive in angled rod for selector shaft -arrow- to stop of tool.   Note Angled rod must be released while it is being driven in.

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-

Driving in selector shaft bearing bush to stop of tool

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.

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.

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“.

Drive in stop sleeve with shoulder until tool makes contact l  Clutch housing bolted to gearbox housing.

Drive in stop sleeve without shoulder until tool makes contact l  Clutch housing bolted to gearbox housing.

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.

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.

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-

Driving in selector shaft bearing bush -A- to stop of tool.

Driving out plug -1- –  Drive plug -1- outwards -arrow- from inside gearbox housing.

Driving in plug -1- –  Drive in sealing plug to dimension -a-, approx. 3 mm below upper edge of housing, using drift -3264-.