Transmission Housing

Special tools and workshop equipment required 

• Driving Sleeve VW 244 B
• Transmission Support VW 353
• Thrust Plate VW 401
• Thrust Plate VW 402
• Punch VW 407
• Tube 37 mm Dia. VW 416 B
• Guide Piece VW 436 A
• Guide Pin VW 439
• Slide Hammer-Complete Set VW 771
• Holding Fixture VW 801
• Guide Piece 10-15
• Thrust Pad 3124
• Bearing Driver 3264
• Subframe Support Assem. Device 3290
• Torque Wrench (5-50 Nm) V.A.G 1331
• Drift T10168
• Drift T10169 or T10362, seeFig 11
• Thrust Piece T10203
• Kukko Extractor 14.5-18.5 mm 21/2
• Kukko Extractor 23.5-30 mm 21/4
• Kukko Support 22/2
• Thread Adapter from Kukko Support 22/1

Fig 1: Exploded View Of Transmission Housing Components As Of Transmission Manufacture Date 190503

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Transmission Housing 
   • When replacing: adjust the output shaft and differential, refer to ADJUSTMENT OVERVIEW .
   • Changes to the grooved ball bearing/input shaft mount area, see "Transmission Housing" under: INPUT SHAFT .
   • Changes to the sealing cap/input shaft mount area, see "Sealing Cap" in item:  4.
2. Cover 
   • Removing, refer to Fig 2.
   • Installing, refer to Fig 3.
3. Oil Drain Plug 
   • Tightening specification, refer to Figure.
4. Seal 
   • Always replace, if equipped.
5. Transmission Fluid Fill Plug 
   • Tightening specification, refer to Figure.
6. Locking Pin 
   • For adjusting the shift mechanism. Refer to SHIFT MECHANISM, ADJUSTING .
   • Can be replaced with the transmission assembled.
   • Removing, refer to Fig 4.
   • Installed position, refer to Fig 5.
   • Installing, refer to Fig 6.
7. Bushing 
   • For the selector shafts with selector forks.
   • Removing, refer to Fig 7.
   • Installing, refer to Fig 8.
8. Retaining Sleeve 
   • Removing when the transmission is disassembled, refer to Fig 9.
   • Removing when the transmission is assembled, refer to Fig 10.
   • Different retaining sleeves, refer to Fig 11.
   • Installing a retaining sleeve with a shoulder. Refer to Fig 12.
   • Installing a retaining sleeve without a shoulder. Refer to Fig 13.
9. Needle Sleeve 
   • For the reverse shaft.
   • Replace after removing.
   • Removing, refer to Fig 14.
   • Installing, refer to Fig 15.
10. Outer Race/Tapered Roller Bearing 
    • Output shaft, 5th, 6th and reverse gears.
    • Removing and installing, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS .
    • When replacing: adjust the output shaft for 5th/6th and reverse gears. Refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
11. Adjusting Shim 
    • Output shaft, 5th, 6th and reverse gears.
    • Adjustment overview, refer to ADJUSTMENT OVERVIEW .
12. Outer Race/tapered Roller Bearing 
    • Output shaft, 1st to 4th gears.
    • Removing and installing, refer to OUTPUT SHAFT, 1ST TO 4TH GEARS .
    • Adjust, if the output shaft for 1st to 4th gears is replaced. Refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING .
13. Adjusting Shim 
    • Output shaft, 1st to 4th gears.
    • Adjustment overview, refer to ADJUSTMENT OVERVIEW .
14. Outer Race/Tapered Roller Bearing 
    • For the differential
    • Removing and installing, refer to DIFFERENTIAL .
    • When replacing: adjust the differential, refer to ADJUSTMENT OVERVIEW .
15. Adjusting Shim 
    • For the differential.
    • Adjustment overview, refer to ADJUSTMENT OVERVIEW .
16. Bushing 
    • For the gear shift shaft.
    • Removing, refer to Fig 16.
    • Installing, refer to Fig 17.
17. Plug 
    • Removing, refer to Fig 18.
    • Installing, refer to Fig 19.
18. Shaft Seal 
    • For the left flange shaft.
    • Removing and installing, refer to LEFT FLANGE SHAFT AND SEAL .

Fig 2: Identifying Screwdriver To Knock Through Rubber At Center Of Sealing Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pierce the center of the rubber cover -A- with a screwdriver -B- and pry it out in the -direction of the arrow-.

Fig 3: Identifying Tool To Drive-In Cap Until Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 4: Identifying Screwdriver To Remove Lock Elbow For Selector Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the locking pin in its unlocked position.

-- Guide a screwdriver -A- into the hole for the locking pin -B-.

-- Pry out the locking pin in the -direction of the arrow-.

Fig 5: Identifying Installation Position Of Lock Elbow

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The mark on the locking pin -arrow- must point toward the connection on the clutch slave cylinder -1-.
• Dimension -a- must be approximately 45°.

Fig 6: Identifying Lock Bracket For Selector Shaft Driven-In Up To Tool Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 7: Identifying Tool Assembly To Pull Out Bearing Bushing For Selector Rod

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Internal puller 14.5 to 18.5 mm, for example, kukko extractor 14.5-18.5 mm 21/2

B - Counter support, for example, kukko Support 22/2

Fig 8: Identifying Tool To Drive-In Bearing Bushing For Shift Rod To Tool Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 9: Identifying Press Lock Sleeve Off With Transmission Removed

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the transmission housing on the thrust plates VW 401 and VW 402 so that the alignment sleeves inside the transmission housing do not get damaged.

Fig 10: Identifying Lock Sleeve For Non-Disassembled Transmission Driven-Out Using Guide Pin 10 - 15

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Locking pin and selector shaft removed.

-- Turn the transmission so that the retaining sleeve cannot fall into the transmission.

Fig 11: Identifying Lock Sleeve Differentiation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The following locking sleeves may be installed:

Locking sleeve with a shoulder -arrow 1-, refer to Fig 12.

Locking sleeve without a shoulder -arrow 2-, refer to Fig 13.

Fig 12: Identifying Tools To Drive In Lock Sleeve With Shoulder As Far As Stop On Tool

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The transmission housing is bolted to the clutch housing.

Fig 13: Identifying Tools To Drive In Lock Sleeve Without Shoulder As Far As Stop On Tool

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The transmission housing is bolted to the clutch housing.

Fig 14: Identifying Tool Assembly To Pull Out Needle Bearing For Reverse Shaft Of Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Internal puller 23.5 to 30 mm, for example, kukko extractor 23.5-30 mm 21/4

B - Counter support, for example, kukko Support 22/2

Fig 15: Identifying Needle Bearing - A - Pressed Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- While installing, place the thrust washer -B- for the reverse shaft onto the needle sleeve -A-.

-- Support the transmission housing beneath the bearing mount using the tube 37 mm dia. VW 416 B.

Fig 16: Identifying Tool Assembly To Remove Selector Shaft Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the thread adapter from the kukko Support 22/1 -arrow-.

-- Hold the spindle on the subframe support assem. Device 3290 and turn the nut -B-.

A - Internal puller 14.5 to 18.5 mm, for example, kukko extractor 14.5-18.5 mm 21/2

Fig 17: Identifying Tool T10168 To Drive-In Bearing Bushing For Selector Shaft Tool To Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 18: Identifying VW 436A To Drive Out Sealing Plugs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the plug -1- from the inside of the transmission housing to the outside.

Fig 19: Identifying Bearing Driver 3264 To Drive In Sealing Plugs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the plug -1- approximately 3 mm under the upper edge of the housing -a- using the bearing Driver 3264.