Disassembly And Assembly: Transmission: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Holding Plate VW 309
Transmission Support VW 353
Needle Bearing Drift VW 295
Driving Sleeve VW 244 B
Hot Air Blower V.A.G 1416
Torque Wrench (5-50 Nm) V.A.G 1331
M8 x 100 mm Bolt
Bracket 30-211A
Driving Sleeve 32 - 111
Thrust Piece T10030/4
Tube 37 mm Dia. VW 416 B
Puller T10408
Support Bridge T10323
Subframe Support Assembling Device 3253/7
Thrust Pad Con. 8/65 VW 433
Thrust Piece 40 - 105
Torque Wrench (40-200 Nm) V.A.G 1332
Kukko Puller (80-210 mm) 18/1 (quantity: 2)
Inductive Heater VAS 6414
Sealant AMV 188 200 03
M7 x 35 bolts with washers (components of the puller T10408)

Disassembling

-- Remove the clutch release lever, the release bearing and the guide sleeve. Refer to CLUTCH RELEASE MECHANISM OVERVIEW .

Be careful not to damaged the bearing for the input and output shafts when removing and installing the 5th gear.
When securing the transmission to the VW 353, mount the following tools for support:

Fig 1: Identifying Transmission Securing Tool
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Under the Input Shaft:

30-211A
32 - 111
T10030/4

-- Secure the bolt on the 30-211A with the nut -A-.

Under the Output Shaft Bracket

T10323
3253/7
VW 433

-- Secure the transmission on the VW 353.

Fig 2: Identifying Transmission On Repair Stand

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the drip tray underneath.

-- Open the oil fill plug and the oil drain plug.

-- Drain the transmission fluid.

-- Remove the transmission housing cover -arrow-.

Fig 3: Identifying Transmission Housing Cover

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Install the 5th gear shift fork as follows:

Fig 4: Identifying Installation Of 5th Gear Shifter Fork

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-- Cover the openings in the transmission housing with a cloth.

-- Move the shift fork -1- into neutral.

-- Remove the bolt -2- with the shift jaw for 5th gear.

-- Remove both bolts -arrows- for the pivot pin.

-- Remove the pivot pin.

-- Remove the 5th gear shift fork.

-- It is not necessary to remove the spring -3- and the locking collar -4-.

-- Engage the 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and then remove the bolts -A- for the synchronizer hub and for the 5th gear wheel.

Fig 5: Identifying Input Shaft And Output Shaft (Locked As Shown)

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-- The input shaft and the output shaft are blocked after both gears are engaged. The synchronizer hub and the gear wheel cannot turn. Both bolts can be loosened now.

NOTE:

Remove any locking compound residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.

-- Remove both bolts -arrows- for the reverse shaft support.

Fig 6: Identifying Reverse Shaft Support Bracket Bolts

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-- Remove the 3rd bolt -arrow- from the reverse shaft support.

Fig 7: Identifying 3rd Bolt For Reverse Gear Shaft Support

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-- For transmissions on vehicles with the stop/start system: remove the transmission neutral position sensor -G701- -arrow-.

Fig 8: Identifying Transmission Neutral Position Sensor

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-- Move the shift shaft into neutral and remove the shift shaft with the shift cover. Remove the bolts -arrows- and pull the shift shaft out of the transmission housing.

Fig 9: Identifying Selector Shaft Bolts

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-- Remove the cover -A- and pivot pin -B- from the bottom of the transmission.

Fig 10: Identifying Removal Of Sealing Cap And Pivot Pins On Underside Of Transmission

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-- Remove the pivot pins -A- on the top side of the transmission and bolts -B- for the transmission housing to clutch housing in area of differential.

Fig 11: Identifying Removal Of Pivot Pins On Top Side Of Transmission And Bolts For Transmission Housing To Clutch Housing In Area Of Differential

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-- Remove the bolts -A- that connect the clutch and transmission housing.

Fig 12: Identifying Inside Clutch Housing Bolts & Output Shaft Bearing Support Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Do not remove the nuts -B- for the bearing mount on the output shaft.

-- Remove both flange shafts.

Fig 13: Identifying Flange Shafts

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-- Remove the flange shafts with the springs, thrust washers and tapered rings.

Remove the following components together with the transmission housing:

5th gear synchronizer hub
5th gear wheel

Both T10408/3 must be attached to the 5th gear.

Fig 14: Identifying T10408/3
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
The straps must be located above the 2 ribs on the housing, opposite each other -arrows-.

NOTE:

There is a needle bearing under the 5th gear wheel.

Secure the straps so that the needle bearing does not touch the 5th gear when removing the transmission housing.

Use the T10408 together with the following special tools:

Fig 15: Identifying T10408 And T10408/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

T10408/2
T10408/3
18/1 (quantity: 2)

-- Install the T10408 in the threaded holes in the transmission housing cover using the bolts -A-.

A - M7 x 35 bolts with washers

Tightening specification: 18 Nm

-- Mount the T10408/2 on the shafts.

-- Install the 18/1.

Fig 16: Identifying Mounting Of T10408/2

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-- Remove the 5th gear synchronizer hub, the 5th gear and the transmission housing by tightening the spindles -A- (1/2 turn) alternating.

-- Warm the 5th gear slightly using the V.A.G 1416.

-- Remove the shift forks -A- together with the shift rails.

Fig 17: Identifying Shift Forks & Reverse Gear Selector Mechanism

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-- Remove the shift mechanism/reverse gear -B-.

-- Remove the nuts -B- from the bearing mount/output shaft.

Fig 18: Identifying Inside Clutch Housing Bolts & Output Shaft Bearing Support Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the reverse gear -A-, the input shaft -B- and the output shaft -C-, one after the other, from the clutch housing.

Fig 19: Identifying Reverse Gear, Input Shaft And Output Shaft From Clutch Housing In Sequence

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-- Remove the differential.

Assembling

-- Install the differential.

-- Always replace the seals -arrows- for the bearing mount/output shaft.

Fig 20: Identifying Output Shaft Bearing Support Sealing Rings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The illustration only shows 3 of the 4 seals.

-- Insert the output shaft -1- and output shaft -2- together.

Fig 21: Identifying Output Shaft, Reverse Gear Drive Gear & Reverse Shaft

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-- Tighten the output shaft bearing mount nuts to specification, see -item 11- 11.

-- Mount the reverse gear -3- on the needle bearing inside the clutch housing.

Shoulder -arrow- faces away from clutch housing.

-- Make sure the reverse shaft -4- is complete, refer to REVERSE SHAFT ; do not mount the support on the reverse shaft.

-- Install the reverse shaft into the clutch housing.

-- Clean all threaded holes in the reverse shaft supports of locking compound; cleaning can be done with a thread tap.

-- Mount the reverse shaft support.

-- Install the reverse gear shift fork -1- with the support for the reverse gear shift fork -2-, the spring -3- and the sliding piece -4-.

Fig 22: Identifying Reverse Gear Shift Fork Installed With Support For Reverse Gear Shift Fork, Spring And Sliding Piece

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Reverse gear location

Fig 23: Identifying Reverse Gear Installation Position

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-- Install the shift mechanism/reverse gear -A-.

Fig 24: Identifying Reverse Gear Selector Mechanism, Selector Forks & Gear Supports

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-- Install the shift forks -B- together with the shift rails.

Reverse gear supports -C- are located in front of the selector rails.

-- Install the M8 x 100 stud bolts -A- into the reverse shaft support so that the shaft is aligned after fitting the transmission housing.

Fig 25: Identifying Studs Installed Into Reverse Shaft Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the shift rails.

NOTE:

The shift segments must be installed in the grooves on the locking collars.

-- Apply sealant AMV 188 200 03 evenly over the sealing surface on the clutch housing.

-- Install the transmission housing.

Install the bolts for the reverse shaft support -arrow- as follows:

Fig 26: Identifying Bolts For Reverse Gear Shaft Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the bolt -a-.

-- Remove the stud bolt -A- (→ upper illustration).

-- Install the bolt -c-.

Tightening sequence:

-- Tighten the bolt -a- to 30 Nm.

-- Tighten the bolt -b- to 25 Nm.

Fig 27: Identifying Bolt

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-- Tighten the bolt -c- to 25 Nm (→ upper illustration).

-- Install the pivot pin -arrow- for the shift forks. To do this align the shift mechanism using a screwdriver, so that the relevant pivot pin can be installed.

Fig 28: Identifying Selector Mechanism Aligned With Screwdriver To Install Pivot Pin

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-- Apply the sealant AMV 188 200 03 evenly on the sealing surface on the sealing cover.

-- Install the shift shaft cover.

Install the shift shaft cover as follows:

Fig 29: Identifying Selector Shaft With Selector Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the shift rail into the neutral position.

-- Apply the sealant AMV 188 200 03 evenly on the sealing surface on the cover.

-- Move the shift shaft into neutral.

-- Position the selector shaft so that selector finger -arrow- is inserted into the selector rails.

-- Tighten the selector shaft selector cover specification, see -item 17- 17.

-- For transmissions on vehicles with the stop/start system: install the transmission neutral position sensor -G701- -arrow- and tighten the bolt to specification, see -item 11- 11.

Fig 30: Identifying Transmission Neutral Position Sensor

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-- Install both flange shafts with springs, thrust washers and tapered rings.

Fig 31: Identifying Both Flange Shafts With Springs, Thrust Washers And Tapered Rings

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