Transmission housing, shift mechanism, input shaft, output shafts (pinion shafts), differential, bevel gear transfer case and selector rods, removing and installing: Removing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Transmission for vehicles with 6-cylinder engine

Fig 1: Securing Transmission To Assembly Support With Bolts (6-Cyl. Engines)

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Secure transmission to assembly stand with bolts - arrows -.

Transmission for vehicles with 4-cylinder engine

Fig 2: Securing Transmission To Assembly Support With Bolts (4-Cyl. Engines)

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Secure transmission to assembly stand with bolts - arrows -.

Continuation for all transmissions

Rotate transmission in assembly stand with oil drain plug downward.
Place drip tray underneath.
Drain gear oil from manual transmission and bevel gear transfer case.

Fig 3: Identifying Bevel Gear Transfer Case/Manual Transmission Bolts, V.A.G 1669, V.A.G 1331 & VW 353

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Remove bolt for right flanged shaft using socket V.A.G 1669 or 6 mm socket insert (commercially available).

NOTE:

Right flanged shaft remains in bevel gear transfer case.

Remove four connecting bolts (only three depicted in illustration) for bevel gear transfer case/manual transmission - arrows -.
Press bevel gear transfer case from manual transmission.

Fig 4: Identifying Slave Cylinder With Release Bearing

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Remove slave cylinder with release bearing - arrows -.
Bring selector shaft into idle position.

Fig 5: Identifying Back-Up Light Switch, Selector Shaft Cover Plate Hex Bolts, Selector Shaft Gate Locking Bolt & Selector Shaft Cover Bolts

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Remove switch for back-up lights - 1 -.
Unscrew hex bolts - 2 - for selector shaft cap - A -.
Carefully remove cap.
Remove securing bolt - 3 - for selector shaft gate.

Remove bolts - 4 - and press off shift cover - B - from transmission housing.
Pull selector shaft off transmission housing.
Remove left flanged shaft.

Fig 6: Identifying Transmission Housing To Clutch Housing Bolts

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Remove mounting bolts - A - for transmission housing at clutch housing in differential area.

Fig 7: Identifying Interior Clutch Housing Bolts

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Remove bolts - B - inside clutch housing for securing clutch housing to transmission housing.

NOTE:

Hex bolt - arrow - is located outside of bolting flange. It is installed with a washer.

Remove transmission housing, if necessary, and carefully pry up all around alternating between sides on protruding flange. Take care not to damage sealing surfaces.

Fig 8: Identifying Locking Plate Bolt

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As of transmission manufacture date 06040

Remove bolt - arrow - for securing plate (outer race/tapered roller bearing of input shaft).
Remove securing plate.

Continuation for all transmissions

Fig 9: Removing Input Shaft

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Swing input shaft in direction of arrow and remove.
Remove Speedometer Vehicle Speed Sensor (VSS).

Fig 10: Identifying Differential, Output Shafts, Reverse Shaft, Selector Rods & Transmission Housing

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With help of a second technician, carefully remove together differential - 1 - , output shafts - 2 - and - 3 - , reverse shaft - 4 - as well as selector rods - 5 - from clutch housing.
Drive out sealing ring for input shaft using sleeve 30-21.