Volkswagen Workshop Service and Repair Manuals

Dismantle

–  Mount gearbox on repair stand. –  Drain gearbox oil. –  Remove clutch release lever and release bearing → Chapter. –  Remove guide sleeve → Chapter.

–  Remove gearbox housing cover -arrow-.

–  Remove 5th gear selector fork and locking collar as follows: –  Place selector fork -1- in neutral position. –  Remove both bearing pin bolts -2-. –  Remove bearing pins in direction of arrow A. –  Remove selector fork in direction of arrow B. –  Circlip -3- must be removed. –  Now remove locking collar -4- and the locking pieces at the same time. –  Slide locking collar again over synchro hub.

–  Remove the bolts -A- from the synchro-hub and from the gear of the 5th gear; to do so, engange the 5th gear -arrow 1- and the 1st gear -arrows 2 and 3- –  After engaging both gears the input shaft and output shaft are locked, synchrohub and gear wheel cannot turn. Both bolts can now be loosened

–  Pull off synchro hub and 5th gear wheel and remove together with needle roller bearing. A – Two arm puller, for example, -Kukko 20/10- with hook -Matra V/170 -.B – Hexagon bolt M10×20.

–  Remove the 5th gear wheel. A – Two arm puller, for example, -Kukko 20/10- with hook -Matra V/170-. B – Hexagon bolt M10×20. Removal sequence: –  Assemble two arm puller and centralize by turning screw -arrow-. –  Pull gear wheel off with two arm puller, first heat with hot air blower -V.A.G 1416- if necessary.   Note When pulling off the gear wheel ensure that the hooks do not bend outwards, if necessary tighten screw -arrow-. After 5th gear wheel has been removed check for damage

–  Remove both flange shafts. –  Take out flanged shafts along with springs, thrust washers and tapered rings.

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

–  Remove selector shaft with selector mechanism cover, placing selector shaft in neutral position and removing the bolts -arrows-.

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

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

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

–  By alternating between the sides of the protruding housing flange, carefully remove the clutch housing. Be careful not to damage the sealing surfaces.

–  Remove selector forks -A- together with selector stems. –  Unscrew bolt for selector mechanism for reverse gear -B- –  Remove nuts for output shaft bearing support (item. -B-, → Anchor)

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