Transmission Cover: Notes

Special tools and workshop equipment required 

• Arbor VW 204 B
• Drift VW 207 C
• Punch VW 408 A
• Punch VW 411
• Punch VW 412
• Sleeve VW 420
• Sleeve VW 423
• Arbor VW 434
• Sleeve VW 472/2
• Thrust Pad VW 512
• Guide Pin 10 - 15
• Sleeve 40 - 21
• Thrust Pad 3005
• Drift 3138
• Extension 3161
• Support Arm Bearing Inst. Tool 3346
• Guide Bearing Inst. Tool 3347
• Shock Absorber Set T10001
• Pulling Hook T20143
• Drift T40085
• Pressure Sleeve T40103
• Sealing Paste AMV 188 001 02
• Sealing Grease G 052 128 A1

1. Large Securing Bushing
   • For selector shaft
   • Removing and installing REMOVING AND INSTALLING THE LARGE LOCKING BUSHING -1- ON THE GEARSHIFT SHAFT 
   • Installation dimension INSTALLED DIMENSION FOR THE LARGE LOCKING BUSHING -1- INSIDE THE TRANSMISSION COVER 
2. Securing Bushing
   • For the gearshift rail / shift fork
   • Removing and installing, refer to is currently not possible.
3. Needle Bearing
   • Always replace
   • For the side shaft bearing
   • Remove from the transmission cover using the 3138
   • Driving in INSTALLING THE NEEDLE BEARING ALL THE WAY INTO THE TRANSMISSION COVER 
   • Secure after installing with peen SECURING THE NEEDLE BEARING INSIDE THE TRANSMISSION COVER BY PEENING IT 
4. Oil Collector Tray
   • Install in the openings in the transmission cover and roller sleeves -6-
5. Outer Race / Tapered Roller Bearing
   • For the gear wheel mounting inside the transmission cover
   • Removing PRESSING TAPERED ROLLER BEARING OUTER RACE OUT FROM THE TRANSMISSION COVER 
   • Installing INSTALLING THE OUTER RACE / TAPERED ROLLER BEARING ALL WAY INTO THE TRANSMISSION COVER 
6. Roller Sleeve
   • For the input shaft mounting
   • Removing REMOVING THE INPUT SHAFT ROLLER SLEEVE FROM THE TRANSMISSION COVER 
   • Installing INSTALLING THE INPUT SHAFT ROLLER SLEEVE -A- ALL THE WAY INTO THE TRANSMISSION COVER 
7. Transmission Cover
8. O-Ring
   • Always replace
   • Installed only on transmissions with a cover / gearshift shaft together with a transmission neutral position sensor -G701- or cap
9. Sealing Cap
   • For the gearshift shaft together with a transmission neutral position sensor or a cap
   • Not present on all versions
   • Allocate according to transmission code.
   • Assembly overview ASSEMBLY OVERVIEW - GEARSHIFT SHAFT COVER WITH A HOLE -ARROW- FOR THE TRANSMISSION NEUTRAL POSITION SENSOR -G701- OR CAP 
   • Selector shaft seal, removing and installing GEARSHIFT SHAFT COVER ASSEMBLY OVERVIEW 
   • Remove the gearshift shaft ball sleeve REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER 
   • Install the gearshift shaft ball sleeve INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- UP TO DIMENSION -X- INTO THE COVER -B-, 
10. Sealing Cap
    • Not present on all versions
    • Allocate according to transmission code.
    • Replace the O-ring with a cap, use the transmission code to allocate.
11. Bolt
    • Always replace
    • 10 Nm plus an additional 45° turn
    • Aluminum bolts (M8; 22 mm long)
12. Transmission Neutral Position Sensor -G701-
    • Not present on all versions
    • Allocate according to transmission code.
    • Replace the O-ring on the transmission neutral position sensor, allocate according to the transmission code.
13. Sealing Cap
    • For the gearshift shaft without a transmission neutral position sensor or a cap
    • Not present on all versions
    • Allocate according to transmission code.
    • Removing and installing, refer to REMOVING AND INSTALLING THE GEARSHIFT SHAFT COVER -A- 
    • Assembly overview GEARSHIFT SHAFT COVER ASSEMBLY OVERVIEW 
    • Selector shaft seal, removing and installing GEARSHIFT SHAFT SEAL, REMOVING AND INSTALLING 
    • Remove the gearshift shaft ball sleeve REMOVING THE GEARSHIFT SHAFT BALL SLEEVE FROM THE COVER 
    • Install the gearshift shaft ball sleeve INSTALLING THE GEARSHIFT SHAFT BALL SLEEVE -A- EVENLY IN THE COVER -B- 
14. Bushing
    • For the 3rd/4th gear gearshift rail / shift fork
    • Removing REMOVING THE BEARING BUSHING FOR THE 3RD AND 4TH GEAR GEARSHIFT RAIL /. FROM THE TRANSMISSION COVER 
    • Installing INSTALLING THE BEARING BUSHING -A- FOR THE 3RD AND 4TH GEAR GEARSHIFT RAIL / SHIFT FORK ALL THE WAY INTO THE TRANSMISSION COVER 
15. Small Locking Bushing
    • For selector shaft
    • Removing and installing is currently not possible.