Transmission Housing Cover And 5TH Gear

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

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

If the transmission housing must be removed, 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
Bracket 30-211 A
Driving Sleeve 32-111
Thrust Piece T10030/4 from Assembly Tool T10030
Tube 37 mm Dia. VW 416 B
Puller T10309
Two Arm Puller T10040 with Puller Legs T10040/2A
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

Removing

-- Remove the clutch release lever and release bearing. Refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING .

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

Fig 1: Support Tools
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Under the Input Shaft:

Bracket 30-211 A
Driving sleeve 32-111
Thrust piece T10030/4

The input shaft may be supported by the driving sleeve 32-111 only at a later time.

Under the Output Shaft Bracket:

Support bridge T10323
Subframe support assembling device 3253/7
Thrust pad con. 8/65 VW 433

-- Secure the transmission to the transmission support 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

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

Fig 4: Checking Legs T10040/2A For Correct Installation Under 5th Gear

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

The legs T10040/2A can be installed correctly.
5th gear is removed individually, refer to Fig 5.

Fig 5: Installing 5th Gear Shifter Fork

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cover the openings with a cloth.

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

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

-- Remove both selector fork base bolts -arrows-.

-- Remove the selector fork bases.

-- Remove the selector fork.

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

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

Fig 6: Locking Input Shaft And Output Shaft (As Shown)

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-- The input and output shafts are blocked after engaging both gears, the synchronizer hub and the toothed gear cannot turn. Both bolts can new be loosened.

NOTE:

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

Remove 5th gear synchronizer hub together with the locking collar and locking pieces.

Use the puller T10309.

-- First, insert the shell T10309/1 between 5th gear drive gear -A- and 5th gear selector fork mount -B-.

The shell T10309/1 must be placed below the synchronizer ring.

Fig 7: Identifying Puller T10309/1 Placed Below Synchronizer Ring
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- The tool must be pressed into the end position, if necessary.

-- Turn the shell T10309/1 on the opposite side in the -direction of the arrow-.

-- Install the threaded insert T10309/3 into the puller.

Fig 8: Inserting Puller In Threaded Insert T10309/3

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-- Then, install the second shell T10309/1 and place tube T10309/2 on the tool.

-- Check the synchronizer hub for damage, after removing.

-- Replace the synchronizer ring.

-- Remove the 5th gear selector gear with needle bearing.

-- Remove the 5th gear. (shown here on a different transmission).

Fig 9: Identifying Special Puller Tools

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the puller leg -A- first.

B -

Thrust piece 40-105

NOTE:

When remove drive gear, make sure the leg does not bend outward. Check the 5th gear for damage.

Installing

-- Apply the sealing paste AMV 188 200 03 evenly over the sealing surface on the transmission housing cover.

-- Install the transmission housing cover. Refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .

-- Install the clutch release lever with release bearing. Refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING .

-- Fill the transmission fluid. Refer to Pay attention to the following list for the subject - "Transmission Fluid, Checking and Filling" .