Disassembly and assembly sequence: Disassembling

WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

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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