Transmission, disassembling

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Place an oil receptacle underneath transmission.
Drain gear oil.

Fig 1: Securing Transmission To Assembly Stand With Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure transmission to assembly stand with bolts - arrows -.
Tilt transmission on assembly stand to horizontal position.

Fig 2: Identifying Bolt, Leaf Spring & Clutch Release Lever

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Loosen bolt - 1 - and remove leaf spring - 2 -.
Remove clutch release lever - 3 - with release bearing.

Fig 3: Identifying Bolts, Securing Plate, Guide Sleeve & Intermediate Piece

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - and remove securing plate - 1 -.
Pull guide sleeve - 2 - out of transmission housing.
Remove intermediate piece - 3 - from transmission housing.

Fig 4: O-Ring Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry out O-ring - arrow - with a small screwdriver.

Fig 5: Removing Input Shaft Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

To disassemble transmission, you do not need to remove the input shaft grooved ball bearing.
A faulty input shaft grooved ball bearing can be released in a removed but not disassembled transmission according to the procedure → Input shaft grooved ball bearing, replacing in uninstalled but not disassembled transmission .

Move shift shaft to neutral position.

Fig 6: Removing Both Securing Bushings For Selector Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both securing bushings - A - for selector shaft.

NOTE:

Identify these securing bushings so that they are not interchanged with the securing bushings for the selector rods.
The securing bushings were changed shortly after series production Selector shaft securing bushings changed .

Remove bolts - arrows - and remove selector shaft cover - B -.

Fig 7: Identifying Selector Shaft & Dowel Pin

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide selector shaft - A - into transmission up to stop and pull out dowel pin - B -.
Pull out selector shaft.

Fig 8: Identifying Transmission Cover Bolts

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Remove bolts - arrows - and remove torsen housing.
Remove torsen differential from drive pinion/hollow shaft.

Fig 9: Removing Circlip, Shim(s), Inner Race, Outer Race & Spacer Ring

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove circlip - 1 - and shim(s) - 2 - from drive pinion

NOTE:

Note the thickness of the circlip and shim(s).

Remove inner race - 3 - and outer race - 4 -. These components are push fit and can be installed by hand.
Remove spacer ring - 5 - from twelve-point nut on hollow shaft.

Fig 10: Securing Hollow Shaft By Moving Selector Rods

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure hollow shaft by moving selector rods - 1 - to - 4 - in direction of - arrow -.

Fig 11: Locating Twelve-Point Nut On Hollow Shaft

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Loosen twelve-point nut on hollow shaft with socket and key T40097.

A - Torque wrench.

Shift selector rods into neutral position.
Turn transmission in assembly bracket so transmission cover faces up.

Fig 12: Identifying Bolts For Securing Bearing Bracket, Bolt For Securing Reverse Shaft, Connection Screws & O-Ring

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Remove bolts - arrow 1 - (for securing bearing bracket), bolt - arrow 2 - (for securing reverse shaft) and connection screws - A - for transmission cover on transmission housing.

NOTE:

Always replace the O-ring - C -.

Fig 13: Identifying Reverse Gear, Clutch Hub & Magnet

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove reverse gear - 1 - and reverse shaft.
Remove clutch hub - 2 - with synchronizer ring for reverse gear by hand.

Remove magnet - 3 - from transmission housing.

Fig 14: Removing Securing Bushings For Selector Rods

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove securing bushings - 1 - to - 4 - for selector rods.

Fig 15: Removing Locking Collar With Shifter Fork And Reverse Gear Selector Gear

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Remove locking collar - A - with shifter fork - B - and reverse gear selector gear - C -.
Remove thrust washer and selector gears for reverse gear and 1st gear.
Remove 1st gear selector gear with needle bearing and synchronizer rings.

Fig 16: Removing 2nd Gear Selector Gear Together With Inner Race For 1st Gear Selector Gear And Shifter Fork For 1st/2nd Gear From Hollow Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 2nd gear selector gear - C - together with inner race for 1st gear selector gear - D - and shifter fork for 1st/2nd gear - B - from hollow shaft.

A - Two arm puller , e.g. Kukko 20/10 with puller hook 250 mm

Fig 17: Removing/Installing Bearing Bracket With Reverse Shaft Mount & Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bearing bracket - A - with reverse shaft mount - B -.
Remove oil pan - C - from transmission housing.

Fig 18: Guiding Hollow Shaft Together With Input Shaft And Selector Rods Upward Over Drive Pinion

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Then guide hollow shaft - 1 - together with input shaft - 2 - and selector rods - 3 - and - 4 - upward over the drive pinion - arrow -.

Fig 19: Identifying Bolts & Retainer Plate

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Remove bolts - arrows - and retainer plate - A - with shim lying below " S ₄ ".

Fig 20: Removing Drive Pinion From Bore In Transmission Housing

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Carefully remove drive pinion - 1 - from bore in transmission housing - 2 -.

Double angular contact ball bearing outer races - 3 - and - 4 - must not be pulled apart, otherwise the double angular contact ball bearing seal - 6 - can be damaged by the drive pinion face - 5 -. In this case, double angular contact ball bearing must be replaced.