Disassembling And Assembling Transmission Housing, Selector Mechanism, Input Shaft, Output Shafts, Differential And Selector Rods

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Transmission Assembly

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Special tools and equipment

VW 309 Holding plate
VW 313 Support clamp
VW 353 Transmission support
30-21 Sleeve
T40008 Press piece
V.A.G 1331 Torque wrench

Disassembling

Vehicles with 6-Cyl. engines

Fig 2: Securing Transmission To Assembly Support With Bolts (6-Cyl. Engines)

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Secure transmission to assembly support with bolts (arrows).

Vehicles with 4-Cyl. engines

Fig 3: Securing Transmission To Assembly Support With Bolts (4-Cyl. Engines)

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Secure transmission to assembly support with bolts (arrows).
Turn transmission on assembly support with oil drain plug downward.
Place drip tray underneath.
Drain transmission oil.

Fig 4: Identifying Slave Cylinder With Release Bearing

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Remove slave cylinder with release bearing (arrows).
Place selector shaft in neutral 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 back-up light switch -1-.
Remove hex bolts -2- for selector shaft cover plate -A-.
Carefully pull out cover plate.
Remove locking bolt -3- for selector shaft gate.

Remove bolts -4- and press selector shaft cover -B- out of transmission housing.
Pull selector shaft out of transmission housing.
Remove both flanged shafts.

Fig 6: Identifying Transmission Housing To Clutch Housing Bolts

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Remove bolts securing transmission housing to clutch housing -A- in area of differential.

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: The hex bolt (arrow) is located outside the bolting flange. It is installed with a washer.

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

For transmissions from build date 06 04 0

Fig 8: Identifying Locking Plate Bolt

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Unscrew locking plate bolt (arrow) (outer race/tapered roller bearing from input shaft).
Remove locking plate.

Continued for all transmissions

Fig 9: Removing Speedometer Drive

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Swing input shaft in direction of arrow and take off.
Remove speedometer drive.

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

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With help of a second technician, remove differential -1-, output shafts -2- and -3-, reverse shaft -4- and selector rods -5- together from clutch housing.
Drive out input shaft oil seal with sleeve 30-21.