Transmission, disassembling/assembling: Disassembling
WARNING: This page is about a different car, the 1999 Volkswagen GTI, 1998 Volkswagen GTI, 1997 Volkswagen GTI, 1996 Volkswagen GTI, and 1995 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.
- Mount transmission in repair stand.
- Drain transmission oil.
- Remove clutch release lever, clutch release bearing, and release bearing guide sleeve, see Assembly overview - pedal cluster
- Remove transmission housing cover (-arrow-).
- Remove 5th gear shift fork (-arrow-).
- Remove bolts -A- for synchro-hub and 5th gear. To do this, engage 5th gear (arrow -1-) and 1st gear (arrow -2- and -3-)
- After engaging both gears, the input shaft and the output shaft are both locked, and the synchro-hub and gear cannot turn. Both bolts can now be loosened.
- Remove synchro-hub and 5th gear along with needle roller bearing.
- - Two-arm puller and hooks e.g. Kukko 20/10 with Matra V/170 hooks
- - Hex bolt (M10 x 20)
- Remove 5th gear.
- - Two-arm puller and hooks e.g. Kukko 20/10 with Matra V/170 hooks
- - Hex bolt (M10 x 20)
Removal sequence: - Install two-arm puller as shown and center by turning adjustment screw (-arrow-). - Heat gear using VAG 1416 hot air blower, then pull gear off.
NOTE: When removing the gear, make sure that the hooks do not bend outward. If necessary tighten screw (-arrow-). After removing, check 5th gear for damage. - Remove left-side axle flange.
Transmission without springs behind axle flanges:
- Place chisel or spacer -A- under axle flange and pull flange from differential gears by turning bolt -B- (B = previously removed housing bolt). See Fig 7
.NOTE: If the axle flange shaft fails to come out straight, use two spacers -A-, and bolts -B-, positioned opposite each other. Tighten both bolts alternately and evenly.
Transmission with springs behind axle flanges:
- Remove cone -head bolt before removing axle flange.
- Remove bolts (-arrows-) for reverse idler shaft support bracket.
- For inside bolt (-left arrow-) use Torx(R) T45 key, 100 mm (4 in.) long
- Shift selector shaft to neutral, then remove bolts (-arrow-).
- Pull selector shaft assembly with cover from transmission housing.
- Remove cover plate -A- and shift fork pivot pins -B- from underside of transmission.
- Remove shift fork pivot pins -A- from upper side of transmission.
- Remove bolts -B- attaching clutch housing to transmission housing in area of differential.
- Remove remaining bolts -A- from inside clutch housing (attaching clutch housing to transmission housing).CAUTION: Do not yet remove the four nuts -B- for the output shaft bearing support.
- Remove transmission housing.
- If housing won't separate, carefully pry up all around on the protruding housing flange (-arrows-).CAUTION:
- Pry gently and evenly, alternating on all sides.
- Be careful to not damage the sealing surfaces.
- Remove shift forks -A- together with selector plates.
- Remove bolt -B- retaining selector mechanism for reverse gear.
- Remove nuts (qty: 4) for output shaft bearing support nuts (see ASSEMBLING , Fig 12 , item -B-)
- Remove reverse gear -A-, input shaft -B- and output shaft -C-, in that order, from clutch housing.
- Remove right-side axle flange shaft.NOTE: Removal procedure for right-side axle flange is the same as the procedure for the left-side axle flange, see ASSEMBLING .
- Remove differential.
Fig 12: Removing Remaining Bolts -A- From Inside Clutch Housing (Attaching Clutch Housing To Transmission Housing)