Transmission, Disassembly

WARNING: This page is about a different car, the 2014 Volkswagen Tiguan, 2013 Volkswagen Tiguan, and 2012 Volkswagen Tiguan. However, it is still accessible from the selected car via links, so may be relevant.

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.