Transmission, With A Sealing Cap CIRCLIP Or A Plastic Cover: Disassembly

-- Attach the transmission to the assembly stand with the bolts -arrows-.

Fig 1: Identifying Transmission Secured To Assembly Stand With Bolts

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-- Turn the transmission in the assembly stand so that the drain plug is facing down.

-- Place the drip tray underneath.

-- Drain the transmission fluid.

-- Remove the slave cylinder with release bearing bolts -arrows- and the slave cylinder with release bearing.

Fig 2: Identifying Slave Cylinder With Release Bearing

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Make sure the gear shift shaft is not blocked by the locking pin -arrow-.

Fig 3: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move the gear shift shaft into neutral.

-- Remove the backup lamp switch -F4- -1-.

-- Remove the locking screw -2-.

-- Then, remove the bolts -3-.

-- Remove the selector shaft with shift cover -4- from the transmission housing.

-- Remove the left and right flange shaft bolts. To do this, install two bolts into the flange and counter hold the flange shaft using a pry bar.

Fig 4: Identifying Installation Of Flange Shaft

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-- Remove the flange shafts and pressure springs.

-- Remove the bolts -B- that connect the clutch housing to the transmission housing.

Fig 5: Identifying Interior Clutch Housing Bolts

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-- Secure the input shaft as follows:

The stub shaft splines on the input shaft has different lengths on the transmission.

-- Either place the thrust tube VW 455 over the input shaft on the clutch housing.

Fig 6: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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-- Or place the Sleeve 3160 over the input shaft on the clutch housing.

Fig 7: Identifying Separating Tool -A- And Sleeve 3160

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-- Tension the separating tool -A-, for example, kukko separating tool 5-60 mm 17/0, tightly behind the splines on the input shaft.

The back of the separating tool must touch the thrust tube VW 455 or the Sleeve 3160 free of play.

With a Metal Sealing Cap:

Fig 8: Identifying Transmission Housing Without Sealing Cap Circlip

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-- Remove the sealing cap circlip -A-.

-- Pierce the rubber cover -C- in the center using a screwdriver.

Fig 9: Identifying Support, Internal Puller & Cap

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-- Remove the cover from the transmission housing.

A - Counter support, for example, kukko Support 22/1

B - Internal puller 8 to 12 mm, for example, kukko puller 12-14.5 mm 21/1

With a Plastic Sealing Cover:

Fig 10: Identifying Screwdriver To Remove Tabs -A-

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Carefully remove all the tabs -A-. Do not damage the transmission housing when doing so.

-- Pry out the sealing cap.

Fig 11: Identifying Screwdriver To Pry Out Sealing Cap

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• Ensure that the individual cap parts are removed as necessary.

Continuation for all Vehicles:

Remove the locking ring -C- from the grooved ball bearing on the input shaft/transmission housing as follows:

Fig 12: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

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-- Hold one end of the locking ring secure using the screwdriver -A-.

-- Pry the other end out of the groove in the grooved ball bearing in the -direction of the arrow- using the screwdriver -B-.

-- Pry out the rest of the locking ring using the screwdriver -B-.

-- Remove the bolts -A- that attach the transmission housing to the clutch housing.

Fig 13: Identifying Transmission Housing To Clutch Housing Bolts

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-- Install adapter VW 771/40 into the threaded hole in the transmission housing.

Fig 14: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

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-- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100 °C (212 °F) for 10 minutes using a heat gun, for example, V.A.G 1416.

-- Remove the transmission housing from the clutch housing in the -direction of the arrow- using the slide hammer VW 771/1.

-- Remove the separating tool -A- and the thrust tube VW 455 (illustration) or the Sleeve 3160 from the input shaft.

Fig 15: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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A second technician is needed to help remove the shafts from the clutch housing.

-- Lift the differential -1- with the left hand. With the right hand, left the output shaft for 1st to 4th gear together with the selector shafts -2- -arrow A-.

Fig 16: Identifying Differential & Output Shaft Lifted With Selector Rods

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-- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear and reverse gear -3- together with the selector shafts out of the clutch housing -arrow B-

-- Removing the input shaft seal.