Volkswagen Workshop Service and Repair Manuals

Repairing gearbox housing and clutch housing

Special tools and workshop equipment required

t	Drift -VW 295-

t	Adapter -VW 295 A-

t	Thrust pad -VW 447 H-

t	Thrust pad -VW 512-

t	Tube -2040-

t	Thrust piece -VW 454-

t	Gearbox support -VW 353-

t	Spindle from assembly tool -3066-

t	Seal and sleeve for right flange shaft are two parts:

t	Thrust piece -3124-

t	Seal and sleeve for right flange shaft are one part:

t	Multipurpose tool -VW 771-

t	Puller hooks -VW 771/37-

t	Thrust piece -T10148-

1 -	Gearbox housing

q	If renewed: adjust input shaft and differential → Chapter

2 -	Oil filler plug, 35 Nm

3 -	Needle bearing

q	For output shaft

q	Driving out → Fig.

q	Driving in and securing → Fig..

4 -

Shim

q	For input shaft

q	Adjustment overview → Chapter

5 -	Tapered roller bearing outer race

q	For input shaft

q	Removing and installing → Fig.

q	If replaced: Adjust output shaft → Chapter.

6 -	Tapered roller bearing outer race

q	For output shaft

q	Removing and installing → Fig.

q	If renewed: adjust input shaft → Chapter

7 -

Shim

q	For output shaft

q	Adjustment overview → Chapter

8 -	Tapered roller bearing outer race

q	For input shaft

q	Removing and installing → Fig.

q	If renewed: adjust input shaft → Chapter

9 -	Needle bearing

q	Removing and installing → Fig.

10 -	Dowel sleeve

q

Qty. 2

11 -	Clutch housing

q	If renewed → Chapter „Adjustment overview“.

12 -

Ball stud

q	Removing and installing → Item

13 -	Guide sleeve

q	With input shaft seal and vulcanised or bonded O-ring

q	Driving out oil seal → Fig..

q	Driving in oil seal → Fig..

q	Remove guide sleeve to change oil seal

q	If O-ring is damaged or has come loose, renew guide sleeve and O-ring together

14 -	Socket head bolt

q	Removing and installing → Item

15 -

Seal

q	Renewing with gearbox installed → Chapter

16 -

Sleeve

q	For seal → Item.

q	Levering out → Fig..

q	Pulling in → Fig.

17 -	One-piece seal and sleeve

q	If seal is damaged, renew seal and sleeve together

q	Pulling out → Fig.

q	Pulling in → Fig.

18 -	Speedometer drive, 10 Nm

q	For vehicles with ABS, discontinued from 11.02, then sealing plug, 5 Nm

19 -	Oil drain plug, 35 Nm

20 -	Tapered roller bearing outer race

q	For differential

q	Removing and installing → Chapter

q	If renewed, adjust differential → Chapter

21 -

Magnet

q	Held in place by housing joint surface

22 -	Tapered roller bearing outer race

q	For differential

q	Removing and installing → Chapter

q	If renewed, adjust differential → Chapter

23 -

Shim

q	For differential

q	Adjustment overview → Chapter

24 -

Seal

q	Renewing with gearbox installed → Chapter

Driving out needle roller bearing

Driving needle bearing in to stop –  Secure needle bearing in gearbox housing at three points (120° offset) using a punch.

Driving oil seal out of guide sleeve

Driving oil seal into guide sleeve to stop

Levering out sleeve -arrow- using screwdriver

Pulling in sleeve A -  Screw spindle of assembly tool -3066- into threaded piece of differential. B -  Nut M12 with washer –  Turn nut -B- and pull in sleeve using thrust piece -3124- onto stop.   Note With gearbox dismantled, press sleeve in to stop using thrust piece -3124-.

Pulling out sleeve and seal There is a shoulder in the inner diameter of the sleeve. –  To pull out seal and sleeve, apply extractor hooks -VW 771/37- behind shoulder in sleeve. –  Press extractor hooks -VW 771/37- forcefully into sleeve while pulling.

Pulling in sleeve and seal –  Clean seat for seal in gearbox. A -  Screw spindle of assembly tool -3066- into threaded piece of differential. B -  Nut M12 –  Turn nut -B- and pull in sleeve using thrust piece -T10148- onto stop.   Note With gearbox dismantled, press sleeve in to stop using thrust piece -T10148-.