Transmission, Disassembly

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

Special tools and workshop equipment required

Holding PlateVW 309
Transmission SupportVW 353
Thrust TubeVW 455
Slide Hammer-Complete SetVW 771
Adapter VW 771/44
Support BridgeT10323
Socket and Extended BitT10107 A
Counter-Hold Tool3435
Thrust PieceT10042
Counter Hold ToolT10371
Thrust PieceT10233
Heat GunV.A.G 1416
Kukko Extractor 14.5-18.5 mm21/2
Kukko Separating Tool 5-60 mm17/0
Kukko Support22/1
Front and Rear Bearing Tool3348/2
Sealing PasteAMV 188 200 03
Universal GreaseG 060 735 A2

Disassembly

-- Install the transmission to the transmission supportVW 353 with the bolts -arrows-.

Fig 1: Attaching Transmission To VW 353 With Bolts

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-- Use holes -1 and 2-.

Fig 2: Identifying Holes -1 And 2-

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

-- Remove the bolt -arrow B- for the right stub shaft.

-- Remove the stub shaft.

-- Place a drip tray under the transmission.

-- Drain the transmission fluid.

-- Remove the clutch housing to transmission housing bolts.

-- Install the thrust tubeVW 455 over the input shaft on the clutch housing and secure the input shaft -B-.

Fig 3: Mount VW 455 Over Input Shaft On Clutch Housing And Secure Input Shaft

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

The back of the separating tool must touch the thrust tube free-of-play.

-- Move the shift unit selector shaft into the neutral position.

Ignore the -arrow-.

Fig 4: Identifying Backup Lamp Switch -F4- -A-, Shift Unit -B- Bolts & Nuts -C-

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

-- Remove the shift unit -B- bolts.

-- Remove the shift unit from the transmission housing; while doing this, rotate the shift unit 180° when removing it.

The shift unit shift fingers must be guided through the selector rods.

-- Remove the nuts -C-.

-- Remove the trip recorder sensor -G75- -A- bolt -arrow- and sensor, if equipped.

Fig 5: Identifying Trip Recorder Sensor -G75- -A- Bolt -Arrow-

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-- Remove the screws and the retainer plate -1-.

Fig 6: Removing Locking Plate

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-- Or, remove the stud bolt -arrow- and retaining bracket -2-.

Fig 7: Identifying No Threaded Bores In Area Of Sealing Cap

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-- Push through the center of the sealing cap -C- using a screwdriver.

Fig 8: Pushing Rubber Through Center Of Cover Using A Screwdriver

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-- Pry the sealing cap out of the transmission housing.

-- If necessary, pull the cap off the transmission housing.

A - Support, for example 22/1

B - Extractor 14.5-18.5 mm, for example 21/2

Remove the locking ring -C- from the input shaft grooved ball bearing as follows:

Fig 9: Removing Locking Ring From Input Shaft Grooved Ball Bearing

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-- Hold one end of the locking ring with a screwdriver -A-.

-- Pry the other end of the locking ring out of the groove in the grooved ball bearing -arrow- with a second screwdriver -B-.

-- Reposition the screwdriver -B- and pry the locking ring out further.

-- Counter hold the stub shaft using the counter hold toolT10371 and remove the bolt for the left stub shaft -A-.

Fig 10: Bolt Together Transmission Housing And Clutch Housing

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-- Remove the stub shaft.

-- Remove the transmission housing to clutch housing bolts.

NOTE:

If the bolts -B- are present, then these do not need to be removed in order to remove the transmission housing.

-- Install the adapter VW 771/44 all the way into the threaded bore in the transmission housing and secure it with the nut -A-.

Fig 11: Installing VW 771/44 Into Threaded Bore In Transmission Housing And Secure It With Nut

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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.

-- Separate the transmission housing from the clutch housing using the slide hammerVW 771 and the adapter VW 771/44. At the same time separate the transmission housing on the housing brace -arrow- from the clutch housing with a pry bar -B-.

-- Remove the separating tool -A- and the thrust tubeVW 455 from the input shaft -B-.

Fig 12: Mount VW 455 Over Input Shaft On Clutch Housing And Secure Input Shaft

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-- Remove the reverse gear selector fork -A-.

Fig 13: Remove Switching Rockers For Reverse Gear

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-- Carefully bring the transmission into a slightly angled position, if necessary.

-- Lift the input shaft -1- in the -direction of the arrow- just enough until it is possible to insert the counter-hold tool3435.

Fig 14: Carefully Bring Transmission Into A Slightly Angled Position If Necessary

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-- Rotate the transmission back into its original horizontal position.

-- Attach the stub shaft -1- to the differential; this way the differential can be raised in the following work steps.

Fig 15: Attach Stub Shaft To Differential This Way Differential Can Be Raised

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-- Remove the 3rd and 4th gear output shaft -2- together with the selector shaft with selector fork -3-.

-- Carefully bring the transmission into a slightly angled position.

-- Push the 1st and 2nd gear output shaft -B- all the way up.

Fig 16: Carefully Bring Transmission Into A Slightly Angled Position

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-- Then remove the reverse gear output shaft -A-.

CAUTION:

When the transmission is in an angled position, components of the transmission could come loose.

To prevent this, move the transmission back into its original horizontal position.

-- Then remove the 1st and 2nd gear output shaft -B- together with the selector shaft with selector rod -C- from the clutch housing.

-- Remove the input shaft -1- together with the selector shaft with selector rod -2-.

Fig 17: Removing Input Shaft Together With Selector Rod

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-- Remove the differential -3- from the stub shaft.

-- Remove the input shaft seal.

NOTE:

Always replace the grooved ball bearing -item 16- in INPUT SHAFT OVERVIEW on the input shaft.