Transmission, Disassembling And Assembling

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Special tools and workshop equipment required

Bearing Driver - Multiple Use VW244B
Press Piece - Multiple Use 40-105
Socket - Xzn 14 T10061
Puller - Crankshaft/Power Steering Seal T20143
Seal Installer - Shaft Seal T40166
Puller - Clutch Module T40176
Seal Installer - Steering Rack3013
Gearbox Support T40206
Gearbox Assembly Tool T40213
Gearbox Support Tool T40214
Selector Shaft Guide Pin T40216
Counterhold - Side Shaft T40217
Clamping Sleeve 3116
Counterhold - Output Shaft T40215
Locking Fluid AMV 185 101 A1
Sealing Compound AMV 188 001 02
Grease for Clutch Disc Shaft Splines G 000 100
Grease G 000 150
Sealing Grease G 052 128 A1

Center Differential Housing, Center Differential, Side Shaft, Transmission Cover, Input and Output Shafts Together with Transmission-Side Shift Mechanism, Removing and Installing

NOTE:

You do not need to remove the differential when removing the components listed above.

Follow the general repair instructions. Refer to REPAIR INFORMATION .

Transmission, disassembling

-- Place the Drip Tray underneath.

Fig 1: Locating Transmission Fluid Drain Plug

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-- Remove the plug -arrow- and drain the transmission fluid.

-- Secure the transmission to the engine/transmission holder. Refer to SECURING ON ENGINE AND TRANSMISSION HOLDER .

Fig 2: Lifting Transmission

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-- Remove the clutch module. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

-- Carefully set down the clutch module, for example, on a workbench.

-- Remove the clutch release lever -1- together with the release bearing -2- and the spring -3-.

Fig 3: Identifying Clutch Release Lever Components

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-- Remove the bolts -4-, the locking plate -5- (if equipped) and the guide sleeve -6-.

-- Pry out the input shaft seal.

Fig 4: Removing Input Shaft Seal

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-- Circlip -arrow- in front of the ball bearing of input shaft must then be removed.

Fig 5: Circlip In Front Of Ball Bearing Of Input Shaft Must Then Be Removed

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NOTE:

If it is not possible to remove the locking ring, then remove the transmission cover first and then move the input shaft forward using a rubber hammer.

-- Push the cover -A- for the output shaft in the center and pry it out in -direction of arrow-.

Fig 6: Push Cover -A- For Output Shaft In Center And Pry It Out In Direction Of -Arrow-

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-- Remove the center differential housing -C-. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING .

Fig 7: Attaching Center Differential Housing To Transmission Cover Using Bolts

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Loosen the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

Fig 8: Identifying Pinion Side Shaft Bolt

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-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the Counterhold - Side Shaft T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Secure the Counterhold - Side Shaft T40217 to the transmission cover with the M8 bolts -arrows-.

Fig 9: Secure T40217 To Transmission Cover With M8 Bolt

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-- Remove the side shaft twelve-point bolt on the pinion.

-A- Torque Wrench

-- Mount the Counterhold - Output Shaft T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Fig 10: Mount T40215 All The Way Onto Spur Gear For The Side Shaft And On Output Shaft

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NOTE:

The Counterhold - Side Shaft T40217 stays attached to the transmission cover.

The output shaft will be blocked after the special tool is installed and will not turn.

-- Now loosen the bolt -A- on the output shaft using the Socket - Xzn 14 T10061

Fig 11: Removing/Installing Bolt -A-

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NOTE:

The bolt -A- has a very high loosening torque (approximately 300 to -350 Nm).

If necessary warm the bolt with the Hot Air BlowerVAG1416 to 80 °C. So that the loosening torque is reduced. After dismantling the transmission check the ball bearing cover in the transmission housing for wear. Replace the ball bearing if necessary.

B - Torque wrench

-- Remove the Counterhold - Output Shaft T40215 and Counterhold - Side Shaft T40217.

-- Remove the side shaft -1- from the transmission cover.

Fig 12: Mounting Spur Gear -2- And Needle Bearing -21- On Output Shaft -3-

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-- Remove the spur gear -2- for the spur gear and the needle bearing from the output shaft -3-.

-- If equipped, remove the Transmission Neutral Position Sensor -G701- -A-.

Fig 13: Identifying Bolt -Arrow- And Remove Transmission Neutral Position Sensor -A-

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-- Remove the bolt -arrow- and remove the sensor from the cover -B-.

NOTE:

The cover -B- remains installed.

If a cap is installed in place of the Transmission Neutral Position Sensor -G701-, the closure cap does not need to be removed when disassembling and assembling the transmission.

-- Remove the Selector Shaft Guide Pins T40216 on the gearshift shaft.

Fig 14: Using Selector Shaft Guide Pin T40216

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-- Remove the bolts -1- and pry the selector shaft cover -2- off carefully.

Fig 15: Bring Selector Shaft Cover -2- Into Contact With Transmission Cover

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-- Lift the gearshift shaft -arrow A- and remove it -arrow B-.

Fig 16: Lift Gearshift Shaft And Remove It

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-- Then turn transmission in assembly bracket so transmission cover -C- faces up.

Fig 17: Mounting Transmission Cover -C- On Transmission Housing -D-

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-- Remove the bolts -A- (for the bearing bracket) and the bolts -B- that attach the transmission cover -C- to the transmission housing -D-.

NOTE:

Make sure the bolt -arrow- is a 50 mm steel bolt when installing the transmission cover.

-- Remove the transmission cover -C-.

Transmission with transmission fluid heating

Fig 18: View Of Transmission Fluid Heat Exchanger

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-- Carefully remove the heat exchanger -1- from the opening in the transmission housing -A arrows-. Pay attention to the guides -arrow B- on the bearing support -2-.

Continuation for all

Fig 19: Installing Oil Catch Tray From Gearshift Rail / Shift Fork For 3Rd And 4Th Gears

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-- Remove the oil catch tray -1- from the gearshift rail/shift fork for 3rd and 4th gears -2- and from the bearing bracket -3- -arrows A through D-.

-- Remove the magnet -5- from the transmission housing and clean it.

Fig 20: Removing Oil Catch Tray -1- From The Gearshift Rail

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NOTE:

Ignore -items 1 through 4-.

-- Rotate transmission in the assembly stand or Engine And Transmission Holder VAS6095 horizontally. The reverse drive gear points -1- with the reverse shaft support -2- upward.

Fig 21: Installing Reverse Drive Gear And Reverse Shaft Support

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NOTE:

Ignore -arrow A- and -arrow B-.

-- Secure the Gearbox Assembly Tool T40213 to the Gearbox Support T40206 using the bolts -arrows-.

Fig 22: Attach T40213 To The T40206 Using Bolts

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CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be removed together.
It is permissible to remove the shaft alternating from side to side by turning each spindle maximum one turn.

-- Remove the input and output shafts from the ball bearings inside the transmission housing by turning the Spindles on the Gearbox Assembly Tool T40213 and alternating from side to side every other turn.

-- At the same time, remove the reverse shaft support -2- from the transmission housing -arrow B-.

Fig 23: Installing Reverse Drive Gear And Reverse Shaft Support

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-- Remove the reverse drive gear -1- and the reverse shaft support -2- from the Drive Axle.

-- Remove the input shaft -1- and the output shaft -2- together with the shift fork group -3- from the transmission housing.

Fig 24: Installing Input Shaft And Output Shaft Together With Shift Fork Group

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-- Remove the oil catch tray -4-.

Remove the Gearbox Assembly Tool T40213 from the Gearbox Support T40206

Assembling the transmission

NOTE:

The adjusting shim for the bearing tension on the spur gear tapered roller bearing must be determined again whenever replacing the transmission cover, the spur gear, the spur gear tapered roller bearing, the gear carrier or the center differential housing. Refer to SPUR GEAR TAPERED ROLLER BEARING PRE-LOAD, DETERMINING .

The reverse drive gear and the reverse shaft support must be installed, before the input and output shafts -1 and 2 - touch the bearing seat in the ball bearing. Refer to Fig 26 .

Fig 25: Installing Input Shaft And Output Shaft Together With Shift Fork Group
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-- Install the oil catch tray -4- and the magnet -5- into the transmission housing.

-- Install the input shaft -1- and the output shaft -2- together with the shift fork group -3- into the transmission housing.

-- Install the reverse drive gear -1- and the reverse shaft support -2-.When doing this, insert the tab -arrow A- into the opening -arrow B- in the transmission housing.

Fig 26: Installing Reverse Drive Gear And Reverse Shaft Support

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-- Attach the Mounts T40214/1 and T40214/2 to the transmission housing using bolts -1- and -2- as shown in the image.

Fig 27: Attaching Support Tools T40214/1 And T40214/2 To Transmission Housing

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-- Connect the Gearbox Assembly Tool - Plate T40213/1 to the Mounts T40214/1 and T40214/2

-- Mount the Press Piece - Multiple Use 40-105 on the input shaft and the Clamping Sleeve 3116 on the output shaft.

CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be installed together.
It is permissible to install the shaft alternating from side to side by turning each spindle maximum one turn.

-- Then install the input and output shafts all the way into the ball bearing by turning the Gearbox Assembly Tool - Spindles T40213/2 alternating from side to side every other turn.

-- Remove the Gearbox Assembly Tool T40213 and Gearbox Support Tool T40214.

-- Install the oil catch tray -1- with the tab -arrow A- into the hole -arrow B- in the bearing bracket -3- and then install the bearing bracket -arrow C- and the gearshift rail/shift fork for 3rd and 4th gears -2- -arrow D-.

Fig 28: Installing Oil Catch Tray From Gearshift Rail / Shift Fork For 3Rd And 4Th Gears

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Transmission with transmission fluid heating.

Fig 29: View Of Transmission Fluid Heat Exchanger

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Replace the o-rings on the heat exchanger.

-- Carefully press in the heat exchanger -1- on the opening in the transmission housing -A arrows-. Insert the guide -arrow B- on the bearing support -2-.

NOTE:

the heat exchanger -1- must be guided when positioning on the housing rib magnets -arrow A - and secured the bearing support guide -arrow B-.

Fig 30: Installing Heat Exchanger

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Continuation for all

-- Make sure the 2 alignment bushings for centering the transmission cover/transmission housing are inside the transmission housing.

-- Apply Sealing Compound AMV 188 001 02 evenly and not too thick on transmission housing joint surfaces on the transmission cover.

-- Mount the transmission cover -C- on the transmission housing -D-.

Fig 31: Mounting Transmission Cover -C- On Transmission Housing -D-

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-- Clean screw threads -A- with a wire brush. Insert the bolts with Locking Fluid AMV 185 101 A1 and install them hand-tight into the bearing bracket.

-- Tighten the new aluminum bolts (quantity:16; 35 mm long) -B- to the tightening specification.

-- Tighten the steel bolt -arrow- (50 mm long) under the hole for the clutch slave cylinder to the tightening specification.

-- Then tighten the bolts -A- to the tightening specification.

Fig 32: Circlip In Front Of Ball Bearing Of Input Shaft Must Then Be Removed

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-- Determine thickest circlip which can still just be installed and insert it.

NOTE:

Begin with the thickest circlip.

The following circlips are available:

Circlip thickness (mm)
3.44	3.47	3.50

-- Mount the spur gear -2- and the needle bearing, refer to -item 24- on the output shaft -3-.

Fig 33: Mounting Spur Gear -2- And Needle Bearing -21- On Output Shaft -3-

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NOTE:

The adjusting shim for positioning the center differential must be determined again when the transmission cover, the spur gear, the spur gear tapered roller bearing or the spacer sleeve are replaced. Refer to ADJUSTING SHIM "S .

-- Install the side shaft -1- all the way into the transmission cover.

Tighten the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

Fig 34: Identifying Pinion Side Shaft Bolt

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-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the Counterhold - Side Shaft T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Secure the Counterhold - Side Shaft T40217 to the transmission cover with the M8 bolts -arrows-.

Fig 35: Secure T40217 To Transmission Cover With M8 Bolt

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-- Tighten the side shaft twelve-point bolt to the pinion to the tightening specification.

-A- Torque Wrench

-- Mount the Counterhold - Output Shaft T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Fig 36: Mount T40215 All The Way Onto Spur Gear For The Side Shaft And On Output Shaft

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NOTE:

The Counterhold - Side Shaft T40217 stays attached to the transmission cover.

The output shaft will be blocked after the special tool is attached and will not turn.

-- Clean the threads -A- on the screw on the output shaft with a wire brush. Insert the bolt with Locking Fluid AMV 185 101 A1 and tighten to the tightening specification.

Fig 37: Removing/Installing Bolt -A-

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B - Torque wrench

-- Remove the Counterhold - Output Shaft T40215 and Counterhold - Side Shaft T40217.

-- Lightly coat the cover -A- for the output shaft with oil on the outer circumference and then install it.

Fig 38: Identifying Output Shaft Cover -A-

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-- Lightly oil outer circumference of new shaft seal for the input shaft.

Fig 39: Installing New Shaft Seal For Input Shaft

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-- Fill the space between the sealing and dust lip halfway with Sealing Grease G 052 128 A1.

-- Drive the new seal in until it is flush without tilting it.

Install the gear carrier on the transmission cover as follows:

Fig 40: Identifying Center Differential Housing

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Installed position: the tab -arrow A- on the gear carrier -2- must installed into the opening -arrow B- inside the transmission cover.

-- Install the oil catch tray -1-.

-- Mount the spacer sleeve -3- and the adjusting shim -4- (for positioning the center differential) on the output shaft.

-- Install the center differential -2- and the center differential housing -6-. Refer to CENTER DIFFERENTIAL HOUSING, REMOVING AND INSTALLING .

Fig 41: Identifying Differential Housing -6-, Pressure Spring -3-, Adjusting Shim -4- & Plate Spring -5-

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-- Install the new o-ring on the selector shaft cover -2-.

Fig 42: Installing T40216 On Selector Shaft

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-- Remove the Selector Shaft Guide Pins T40216 on the gearshift shaft -1-.

-- Install the gearshift shaft into the transmission -arrow A- and lift it slightly -arrow B-.

Fig 43: Installing Gearshift Shaft Into Transmission And Lift It Slightly

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-- Bring the selector shaft cover -2- into contact with the transmission housing.

Fig 44: Bring Selector Shaft Cover -2- Into Contact With Transmission Cover

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-- Tighten the new bolts -1- to the tightening specification.

-- Remove the Selector Shaft Guide Pin T40216.

-- If equipped, install the Transmission Neutral Position Sensor -G701- -A- with a new o-ring into the gearshift shaft cover -B-.

Fig 45: Identifying Bolt -Arrow- And Remove Transmission Neutral Position Sensor -A-

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-- Tighten the new bolt -arrow- to the tightening specification.

-- Install the guide sleeve -6- and the locking plate -5-, if equipped.

Fig 46: Identifying Clutch Release Lever Components

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-- Clean the screw threads -4- with a wire brush. Insert the bolts with Locking Fluid AMV 185 101 A1 and tighten to the tightening specification, refer to OVERVIEW - CLUTCH RELEASE MECHANISM -item 6- "Bolt" (See figure 1).

Fig 47: Lubricating Release Bearing

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CAUTION:

Rattling noises when using the clutch.

-Rattling noises- can occur when pressing the clutch if there is not enough grease on the release bearings arrows
Lubricate the bearing areas -arrows- abundantly on the release bearing with Grease G 000 150. Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .
Lubricate the release bearing areas on the clutch release lever with Grease G 000 150.
Remove any grease still in the guide sleeve bearing area-mounting for the release bearing on the guide sleeve.

-- Install the clutch release lever -1- together with the release bearing -2- and the spring -3-. Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .

Fig 48: Identifying Clutch Release Lever Components

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Fig 49: Checking the needle bearing inside the dual mass flywheel on vehicles with 4-cylinder TDI engine (except on the 125 kW TDI)

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CAUTION:

See which needle bearing is installed inside the dual mass flywheel.

Depending on the version, the ball bearing or needle bearing may have all rollers installed or it may be missing every 4th roller.
If needle bearing -B- is missing every 4th roller -arrows-, it must be replaced on 4-cylinder TDI vehicles (except 125 kW TDI). Refer to DUAL MASS FLYWHEEL NEEDLE BEARING OR BALL BEARING, REPLACING .
On all other vehicles, the missing 4th roller is not a defect in the needle bearing. Do not replace the needle bearing!
Depending on the manufacturer the needle bearing is either completely equipped with rollers -A - or with balls -C-.

Depending on the manufacture vehicles with 4-cylinder TDI engines (except 125 kW-TDI) the following bearing is installed:

>>LuK<< dual mass flywheel: needle bearing -A-, completely equipped with rollers.
>>Sachs<< dual mass flywheel: ball bearing -C-.

-- Install the clutch module and the left flange shaft. Refer to CLUTCH MODULE, REMOVING AND INSTALLING .

Fig 50: Identifying Flywheel Components, Remove/Install

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-- Fill transmission fluid in transmission and check the fluid level. Refer to TRANSMISSION FLUID LEVEL, CHECKING . Remove the oil filler plug -arrow- to do this.

Fig 51: Identifying Oil Filler Plug

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