Transmission Housing Cover And 5TH Gear: Notes

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

NOTE:

If only the 5th gear has to be removed, follow this procedure:

Transmission fluid does not need to be drained for this procedure. When the transmission housing cover is removed, the transmission must sit with the cover side facing upward.

If the transmission housing must be removed, follow the disassembly and assembly procedure. Refer to TRANSMISSION .

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
2-Arm Puller 20/10
M 8 x 100 mm Bolt
Bracket 30-211A
Driving Sleeve 32 - 111
Thrust Piece T10030/4
Tube 37 mm Dia. VW 416 B
Puller T10309
Two Arm Puller T10040
Puller Legs with Thrust Piece T10040/2A+/3
Support Bridge T10323
Subframe Support Assembling Device 3253/7
Thrust Pad Con. 8/65VW 433
Thrust Piece 40 - 105
Torque Wrench (40-200 Nm) V.A.G 1332

Removing

-- Remove the clutch release lever and release bearing. 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 Tools
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Under the Input Shaft:

30-211A
32 - 111
T10030/4

Input shaft may be supported by the 32 - 111 only at a later time.

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.

-- Remove the transmission housing cover -arrow-.

Fig 3: Identifying Transmission Housing Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the T10040/2A can be installed correctly under the 5th gear.

Fig 4: Identifying T10040/2A

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The T10040/2A cannot be installed correctly.
The -A- T10040/2A prematurely touch the : transmission housing wall The ribbing in the transmission housing under the 5th gear wheel	"Combined removal" of the: "5th gear synchronizer hub", " 5th gear" and "transmission housing", refer to TRANSMISSION .
The -B- T10040/2A touch the ribs in the transmission housing under the 5th gear wheel.

The T10040/2A can be installed correctly.
The 5th gear can be removed individually, refer to REMOVING JUST THE 5TH GEAR .