Disassembly and assembly sequence: Disassembling

WARNING: This page is about a different variant/trim than selected.

Mount transmission in assembly stand.

Fig 1: Mounting Transmission In Assembly Stand
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Drain transmission oil.
Remove clutch push rod -A- from input shaft.

Fig 2: Removing Clutch Push Rod From Input Shaft

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Fit input shaft support bridge 30-211 A.
A - Lock nut, M12
Press VW 295a to stop on input shaft using bolt and lock with lock nut -A-.

Fig 3: Fitting Input Shaft Support Bridge
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Loosen bolts for transmission housing cover (arrow) and remove entire assembly.

Fig 4: Loosening Bolts For Transmission Housing Cover And Removing Entire Assembly

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Remove lock bolt (arrow) for selector shaft -A-.

Fig 5: Removing Lock Bolt For Selector Shaft
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Remove Vehicle Speed Sensor (VSS) -G22- -B-.
Use spark plug wrench -A- (part no. 311 012 205 A or equivalent) to loosen selector shaft cover and remove cover together with spring.

Fig 6: Loosening Selector Shaft Cover
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Bring shift forks into neutral position and extract selector shaft.
Remove Torx® bolt (arrow) for reverse idler gear shaft.

Fig 7: Removing Torx® Bolt For Reverse Idler Gear Shaft

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Remove left-side drive flange: see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING .

Fig 8: Removing Left-Side Drive Flange
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Engage 5th gear (arrow -1-).

Fig 9: Engaging 5th Gear
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Engage reverse gear (arrow -2-) (front shift fork slot moved downward).
Remove synchronizer hub retaining bolt using 12 mm 12-point socket-head wrench.

Fig 10: Removing Synchronizer Hub Retaining Bolt

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Press off selector tube securing plate.

Fig 11: Pressing Off Selector Tube Securing Plate

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Turn selector tube counter-clockwise to remove it from shift fork.
CAUTION: DO NOT pull selector rod from selector tube.

Fig 12: Turning Selector Tube Counter-Clockwise

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Remove synchronizer hub together with 5th gear and shift fork, using two levers to pry free if necessary.
CAUTION:
- Take care to avoid damaging the housing sealing surfaces.
- Note the gear thrust washer below the synchronizer hub.

Fig 13: Removing Synchronizer Hub

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Remove circlip and thrust washer for 5th gear.
NOTE: On vehicles with 2.0 liter, 85 kW (115 hp) engine, the 5th gear circlip is replaced by securing plate -A-.

Fig 14: Removing Circlip And Thrust Washer For 5Th Gear

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Remove 5th gear using two-legged puller if necessary.
A - Kukko 20/10 with Matra V 170 hook (or equivalent)

Fig 15: Removing 5Th Gear

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Remove tension bracket for deep groove ball bearing for input shaft (arrow).
Remove socket-head bolts retaining transmission housing.

Fig 16: Removing Socket-Head Bolts Retaining Transmission Housing

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Pull off transmission housing.

Fig 17: Pulling Off Transmission Housing

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Pull selector rod -A- from bore in clutch housing and remove shift fork -B-.
Remove circlip for 4th gear from output shaft.

Fig 18: Pulling Selector Rod From Bore In Clutch Housing And Removing Shift Fork

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Remove 4th gear, using 2 -legged puller if necessary.
A - Kukko 20/10 with Matra V 170 hook (or equivalent)

Fig 19: Removing 4th Gear

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Remove complete input shaft -A-.
NOTE: Reverse gear -B- must not be engaged.

NOTE: Vehicles with 2.0 liter, 85 kW (115 hp) engine are equipped with an additional circlip -A- for 4th gear.

Fig 20: Locating Input Shaft & Reverse Gear

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Remove circlip -A-
Remove circlip -B-.

Fig 21: Locating Circlips

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Press off 3rd gear with 2nd gear.
A - Two-arm puller, e.g. Kukko 20/10 with 250 mm hooks

Fig 22: Pressing Off 3rd Gear With 2nd Gear
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Remove synchronizer ring and needle bearing.
Drive out reverse gear shaft with bolt (threaded in, arrow) using plastic hammer.
Remove reverse gear from relay lever.
Pull off synchronizer hub/operating sleeve and 1st gear together with inner race for needle bearing of 2nd gear.
A - Kukko 20/10 (or equivalent) with 250 mm hook

Fig 23: Pulling Off Synchronizer Hub/Operating Sleeve

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Remove bearing cover bolts (arrows) and cover.
Note thrust washer -1-.
Remove output shaft.
Remove right-side drive flange, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING .

Fig 24: Removing Bearing Cover Bolts And Cover

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Remove differential.
CAUTION: Watch for tapered ring -A- and thrust washer -B- for drive flange spring.

Fig 25: Removing Differential

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