Transmission Housing, Servicing

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Special tools and workshop equipment required 

• Press Piece - Output Shaft Gear/Final Drive Gear :3002 
• Press Piece - Trailing Arm :2010 
• Puller - Grease Cap :VW637/2 
• Drive Sleeve :30-20 
• Thrust Piece and Sleeve :VW 472 
• Press Piece - Multiple Use :VW473 

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Special tools and workshop equipment required 

• Press Piece - Bushing :3118 
• Press Piece - Bushing - 50mm Diameter :VW432 
• Seal/Bearing Installer - Sleeve :32-109 
• Press Piece - Multiple Use :VW412 
• Seal/Bearing Installer - Multiple Use :30-21 
• Slide Hammer Set :VW771 

Special tools and workshop equipment required 

• Press Piece - Bushing :VW434 
  Fig 1: Identifying Press Piece - Bushing VW434

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• Puller - Two Arm :T10040 

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• Internal Puller (Kukko 21-3) :VAS 251601 

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• Counter Support :VAS 251 621 
  Fig 2: Counter Support

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• Press Tool :T40323 

Output Shaft Cover, Removing

-- Remove the caps, to do so sheer on the center of the cap and remove using the Puller - Grease Cap :VW637/2  as shown.

-- Remove the oil catch tray -1-.

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Install the caps for the output shaft 1

-- Press in the new end cover with the Press Tool :T40323  .

• The oil catch tray must be installed.

Remove the pinion roller sleeve 1

• Beforehand, remove the circlip for the roller sleeve  ) Circlip.

2 -

Internal Puller (Kukko 21-3) :VAS 251601 

3 -

Counter Support :VAS 251 621 

TIP:

• The transmission housing can be attached to the Transmission Support :VW 353  for this procedure.

Press in the pinion roller sleeve 1

2 -

Press Piece - Multiple Use :VW412 

3 -

Seal/Bearing Installer - Multiple Use :30-21 

• Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Sleeve :30-21  -3-.

-- Then install the roller sleeve circlip  ) Circlip.

Removing the roller bearing for the output shaft, FWD vehicles

On FWD vehicles the roller bearing for the output shaft is destroyed when removing and must be replaced.

• Beforehand, remove the circlip for the roller sleeve  ) Circlip.

-- Position the Slide Hammer Set - Hook :VW771/37  -3- under the bearing cage and mount rolls -2- and drive out the bearing cage from the bearing shell -1-.

3 -

Slide Hammer Set - Hook :VW771/37 

4 -

Slide Hammer Set :VW771 

-- Then remove the bearing shell -1-.

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2 -

Puller - Two Arm - Arm :T10040/1 

3 -

Puller - Two Arm :T10040 

4 -

Press Piece - Bushing :VW434 

5 -

Press Piece - Output Shaft Gear/Final Drive Gear :3002 

Pressing in the roller bearing 1 for the output shaft, FWD vehicles

-- Support the transmission housing using the Press Piece :VW472/1  -5- directly under the bearing mount.

• Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Press Piece - Trailing Arm :2010  -2-.

2 -

Press Piece - Trailing Arm :2010 

3 -

Drive Sleeve :30-20 

4 -

Press Piece - Multiple Use :VW412 

-- Then install the roller sleeve circlip  ) Circlip.

Driving out the roller sleeve for the output shaft 1, AWD vehicles

-- If equipped, remove the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

• Beforehand, remove the circlip for the roller sleeve  ) Circlip.

2 -

Press Piece - Multiple Use :VW473 

TIP:

• The transmission housing can be attached to the Transmission Support :VW 353  for this procedure.

Pressing in the output shaft roller sleeve, AWD vehicles

• Position the roller sleeve with the labeled side (larger panel thickness) to the Press Piece - Bushing :3118  -1-.

1 -

Press Piece - Bushing :3118 

2 -

Press Piece - Bushing - 50mm Diameter :VW432 

3 -

Drive Sleeve :30-20 

4 -

Press Piece - Multiple Use :VW412 

-- Then install the roller sleeve circlip  ) Circlip.

-- If equipped, install the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

Drive out the input shaft ball bearing 1

2 -

Seal/Bearing Installer - Sleeve :32-109 

• Beforehand, remove the ball bearing circlip  ) Circlip

TIP:

• The transmission housing can be attached to the Transmission Support :VW 353  for this procedure.

Pressing in the input shaft ball bearing 1

Ball bearing installation position: the groove -arrow- all around on the ball bearing points downward to the transmission housing.

2 -

Seal/Bearing Installer - Sleeve :32-109 

3 -

Drive Sleeve :30-20 

4 -

Press Piece - Multiple Use :VW412 

Install the ball bearing circlip 2 on the drive axle 1

• The bevel on the circlip -2- faces away from the ball bearing -1-. The flat side faces the ball bearing.