Transmission housing, shift mechanism, input shaft, output shafts (pinion shafts), differential 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 to point 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 -.

Make sure that selector shaft is not locked by the lock elbow - arrow -.

Fig 5: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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Bring selector shaft into idle position.
Remove mounting screw - 2 -.
Then remove bolts - 3 -.
Pull selector shaft - 4 - off transmission housing.

Remove flanged shaft and stub shaft.

Fig 6: 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.

Fig 7: Securing Input Shaft Using Pressing Sleeve VW 455 & Tensioning Separating Tool

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Secure input shaft by inserting pressing sleeve VW 455 over input shaft onto clutch housing.
Tension separating tool - A - , e.g. Kukko 17/0 tightly behind input shaft splines.

The back side of separating tool must contact pressing sleeve free of play.

Fig 8: Identifying Support, Internal Puller & Cap

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Knock rubber through in center of cap - C - using a screwdriver.
Remove cap from transmission housing.

A - Support , e.g. Kukko 22/1

B - Internal puller 8 to 12 mm , e.g. Kukko 21/01

Fig 9: Removing Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing Using Screwdrivers & VW 309

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Remove circlip - C - from grooved ball bearing of input shaft/transmission housing as follows:

Hold one end of circlip in place using screwdriver - A -.
Using screwdriver - B - , pry other end out of groove for grooved ball bearing - direction of arrow -.
By following with screwdriver - B - , continue to pry out circlip.

Fig 10: Identifying Transmission Housing To Clutch Housing Bolts

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Remove mounting bolts - A - for transmission housing at clutch housing.

Fig 11: Screwing Adapter VW 771/40 Into Transmission Housing, Heating Transmission Housing Using V.A.G 1416 & Removing Transmission Housing From Clutch Housing Using Slide Hammer VW 771/1

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Screw adapter VW 771/40 into threaded hole of transmission housing.
Heat transmission housing using hot air gun , e.g. V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to approx. 100 ° C for approx. 10 minutes.
Remove transmission housing from clutch housing using slide hammer VW 771/1 in direction of - arrow -.

NOTE:

If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.

Fig 12: Securing Input Shaft Using Pressing Sleeve VW 455 & Tensioning Separating Tool

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Remove separating tool - A - and pressing sleeve VW 455 from input shaft.

A second technician is required to remove shafts from clutch housing.

Fig 13: Lifting Differential & Output Shaft With Selector Rods

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Lift differential - 1 - with left hand. With right hand, lift output shaft for 1st to 4th gears together with selector rods - 2 - - arrow A -.
At same time, second technician lifts input, reverse and output shaft for 5th/6th gear - 3 - together with selector rods out of clutch housing - arrow B -.

NOTE:

If necessary, differential can be shifted again in clutch housing after lifting shafts.

Drive out sealing ring for input shaft using sleeve 30-21.