Transmission housing, servicing: Notes
Special tools and equipment
- VW 408 A Press tool
- VW 423 Tube
- VW 454 Thrust pad
- VW 681 Seal extractor
- VW 771 Multi-purpose tool
- 10-15 Guide pins
- 30-100 Thrust sleeve
- 30-505 Fitting mandrel
- 40-503 Inserting drift
- 2062 Fitting drift
- 1 - Kukko 21/2 Internal puller and Kukko 21/5 Internal puller
- VAG 1331 Torque wrench (5 to 50 Nm)
- Depth gauge
- Assembly sleeve Part No. 01E 311 120
1) Adjustments are required if these components are replaced. Refer to Adjustment overview: Refer to Adjustment overview .
1 - Seal for flanged shaft
- Pulling out. See Pulling out seal for flanged shaft
- Tapping in. See Driving in seal for flanged shaft
- Pack space between sealing lips with sealing grease
- Replacing with transmission installed. Refer to Removing input shaft seal when transmission is not disassembled
2 - Cover1)
- For final drive
3 - O-ring
- For cover for final drive
- Always replace
4 - Shim S1
- Note thickness
- Adjustment overview. Refer to Adjustment overview
5 - Taper roller bearing outer race, large1)
- For differential
- Removing and installing. Refer to Driving outer race for large taper roller bearing out of cover and Driving outer race for large taper roller bearing into cover
6 - Taper roller bearing outer race, small1)
- For differential
- Removing and installing. Refer to Driving outer race for small taper roller bearing out of transmission housing and Pressing outer race for small taper roller bearing into transmission housing
7 - Shim S2
- Note thickness
- Adjustment overview. Refer to Adjustment overview
8 - Seal
- For input shaft
- Levering out. See Levering out input shaft seal when transmission is disassembled
- Tapping in. See Drive in input shaft seal flush
- Always replace when removing input shaft
- Replacing when transmission is not disassembled. See Removing input shaft seal when transmission is not disassembled and Drive in input shaft seal flush
9 - Oil drain plug, 40 Nm
10 - Ball sleeve for selector shaft
- Pulling out. See Pulling out ball sleeve
- Tapping in. See Driving in ball sleeve
11 - Ball sleeves for selector rods
- Pulling out as -Item 10 Transmission housing, servicing . See Pulling out ball sleeve
- Driving in as -Item 10 Transmission housing, servicing . See Driving in ball sleeve
12 - Circlip
- Installation position: Eyes facing up
13 - Switch for reversing light, 20 Nm
- Removing and installing. See Removing and installing reversing light switch
14 - O-ring
- For selector shaft cover
- Always replace
- Coat with gear oil when installing
15 - Cover for selector shaft
16 - Ball stud, 20 Nm
- For connecting rod
17 - Taper roller bearing outer race, large1)
- For drive pinion
- Pulling out. Refer to Pulling out large taper roller bearing outer race
- Pressing in. Refer to Heating transmission housing in order to install outer race for taper roller bearing
18 - Circlip
- Removing. See Removing circlip
19 - Shim S3
- Note thickness
- Adjustment overview. Refer to Adjustment overview
20 - Needle bearing for input shaft
- Pulling out. See Pulling needle bearing out of transmission housing
- Tapping in. See Driving needle bearing into transmission housing
- Measuring insertion depth. See Insertion depth of needle bearing
21 - Locking bolt for selector shaft, 50 Nm
- Removing. Refer to Figure
- Insert in transmission housing with sealing paste AMV 188 001 02
22 - Trunnion bolt, 40 Nm
- For push rod
23 - Breather
- Insertion depth of sleeve. See Insertion depth of breather sleeve
- Clip cap on
24 - Selector shaft seal
- Can be replaced when transmission is removed but not disassembled
- Always replace
- Pulling out. See Pulling out selector shaft seal
- Tapping in. See Driving in selector shaft seal
- Always use assembly sleeve for installing. See Installing seal and selector shaft with assembly sleeve
25 - Transmission housing 1)
26 - Solenoid
- Clean
- Drive in (for example, with press tool VW 408 A) when replacing transmission
27 - Speedometer vehicle speed sensor -G22-
- Replacing. Refer to Speedometer vehicle speed sensor -G22-, removing and installing
28 - O-ring
- Always replace
29 - Oil filler plug, 40 Nm