Transmission Cover, Servicing

Special tools and workshop equipment required 

• Bearing Installer - Bearing Press Piece VW207C
• Press Plate VW402
• Press Piece - Rod VW408A
• Press Piece - Rod VW411
• Press Piece - Multiple Use VW412
• Press Piece - 28x210mm VW420
• Press Piece - Shift Rod/Alternator VW423
• Press Piece - Bushing VW434
• Bearing Installer - Pinion Bearing VW470
• Press Piece - Multiple Use - Sleeve VW472/2
• Guide Pins10-15
• Bearing Installer - Multiple Use 40-20
• Press Piece - Multiple Use 3005
• Bearing Installer - Multiple Use 3062
• Shoulder Piece 3161
• Bearing Installer - Multiple Use 3347
• Shock Absorber Set T10001
• Puller - Crankshaft/Power Steering Seal T20143
• Locking Bushing Drift T40085
• Internal Puller 56 to 110 mm, for example, Puller - Kukko Internal 21/89
• Counter Support, for example, Puller - Kukko Counterstay 22/4
• Sealing Compound AMV 188 001 02
• Sealing Grease G 052 128 A1
• Locking Fluid AMV 185 101 A1

Fig 1: Identifying Large Locking Bushing

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• The gearshift shaft must be removed.
• If the transmission is not disassembled, place a cloth in the opening for the gearshift shaft to prevent the locking bushing from falling into the transmission.

-- Remove the large locking bushing inward in the transmission cover using the Locking Bushing Drift T40085.

-- Install the locking bushing to the installation dimension using the Locking Bushing Drift T40085. Refer to Fig 2.

Fig 2: Checking Large Locking Bushing Installed Dimension

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-- Use a Depth Gauge -2- to check the installed dimension -a- = 5 ± 0.2 mm.

• Insert the Depth Gauge on the first shoulder -arrow- of the locking bushing.

Fig 3: Remove the Needle Bearing from the Transmission Cover

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A -

Counter Support, for example, Puller - Kukko Counterstay 22/4

B -

Internal Puller 56 to 110 mm, for example, Puller - Kukko Internal 21/89

Fig 4: Installing Needle Bearing All Way Into Transmission Cover

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Install needle bearings with labeling (side with thicker metal) facing towards the Bearing Installer - Multiple Use 3062.

-- Secure needle bearing after pressing into transmission cover with peen. Refer to Fig 5.

Fig 5: Securing Needle Bearing Inside Transmission Cover

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-- To peen, use blunt center punch with ball-shaped end (ball 5 mm diameter).

-- Needle bearing is secured with 3 peening marks -arrows- every 120° around circumference.

Pay special attention to the position and the diameter of the peen points:

• Dimension -a- = 2 mm
• Dimension -b- = 3 mm.

Fig 6: Pressing Tapered Roller Bearing Outer Race Out

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Fig 7: Installing Outer Race

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Fig 8: Removing & Installing Gearshift Shaft Cover -A-

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• The gearshift shaft is removed.

-- Remove the bolts that attach the cover -A- to the transmission cover.

-- Carefully install the cap using the Press Piece - 28x210mm VW420 direction of -arrow-.

-- Clean the sealing surfaces on the cover and transmission cover.

-- Clean screw threads with a wire brush.

-- Apply Sealing Compound AMV 188 001 02 evenly onto the cap sealing surface on the transmission cover.

-- Install the cap while inserting the bolts with Locking Fluid AMV 185 101 A1 and tighten to the tightening specification, refer to TRANSMISSION COVER ASSEMBLY OVERVIEW -item  10- Bolt (See Figure).

Fig 9: Gearshift Shaft Cover Assembly Overview

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1. Selector Shaft Seal, Removing and Installing. Refer to Fig 11
2. Cap
3. Gearshift Shaft Ball Sleeve. Refer to Fig 12 for removing, and Fig 13 for installing.

Fig 10: Assembly Overview - Gearshift Shaft Cover With A Hole -Arrow- For Transmission Neutral Position Sensor -G701- Or Cap

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1. Selector Shaft Seal. Refer to Fig 11
2. Cap
3. Gearshift Shaft Ball Sleeve. Refer to Fig 12 and Fig 14.
4. O-Ring

Fig 11: Gearshift Shaft Seal, Removing & Installing

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-- Pry out shaft seal with Pulling Hook T20143/1.

-- Lightly coat the outer circumference of the shaft seal with oil.

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

-- Install shaft seal with Shock Absorber Set - Socket T10001/1 or Press Piece - Shift Rod/Alternator VW423.

• Installed dimension: 2 mm under the upper edge of the cover

Fig 12: Removing Gearshift Shaft Ball Sleeve

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Fig 13: Installing Gearshift Shaft Ball Sleeve

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Set ball sleeve in place with labeled side (side with thicker metal) facing toward Guide Pins10-15.

Fig 14: Identifying Gearshift Shaft Ball Sleeve Installed Dimension

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Set ball sleeve in place with labeled side (side with thicker metal) facing toward Guide Pins10-15.

• Installed dimension -x- = 2.5 ± 0.5 mm

Fig 15: Removing 3rd & 4th Gear Gearshift Rail Bearing Bushing

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Fig 16: Installing 3rd & 4th Gear Gearshift Rail Bearing Bushing

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-- Install the Shoulder Piece 3161 with shoulder -arrow 1- in the bearing bushing -A-.

-- Install the bearing bushing all the way using the Bearing Installer - Bearing Press Piece VW207 C while inserting the shoulder -arrow 2- into the Shoulder Piece 3161.