Disassembly

-- Secure the transmission to the Transmission Support VW353.

-- Place a drip tray underneath.

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

-- Drain the transmission fluid.

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

• 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 VW353, install the following special tools for support:
  Fig 2: 30-211A, VW 353 & T10323

  

Under the Input Shaft:

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

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

Under the Output Shaft Bracket:

• Support bridge T10323
• Subframe support assembling device 3253/7
• Thrust pad con. 8/65VW433

-- Remove the transmission housing cover -arrow- .

Remove the 5th gear selector fork as follows:

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

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

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

-- Remove the selector fork bases.

-- Remove the 5th gear 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 then remove the bolts -A- for the synchronizer hub and for the 5th gear.

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

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

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

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

-- Remove the sealing cap -A- and support pins -B- from the bottom of the transmission.

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

-- Remove the clutch housing to transmission housing bolts -A- .

-- Remove both flange shafts.

-- 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

• Both plates T10408/3 must be attached to the 5th gear.
  Fig 13: Identifying T10408/3

  
• The plates T10408/3 must be located above the two ribs on the housing, opposite each other -arrows- .

Use the puller T10408 together with the following special tools:

• Thrust piece T10408/2
• Plates T10408/3
• Puller - Kukko Puller - 60-150mm Width, 200mm Length 18/1 (Qty: 2)

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

A -

M7 x 35 bolts with washers

Tightening specification: 18 Nm

-- Install the thrust pieces T10408/2 on the shafts.

-- Install the Puller - Kukko Puller - 60-150mm Width, 200mm Length 18/1.

-- Tighten the spindles -A- - half on the Puller - Kukko Puller - 60-150mm Width, 200mm Length 18/1 in an alternating order, to remove the 5th gear synchronizer hub, 5th gear and transmission housing.

-- Heat the 5th gear slightly using the Hot Air Blower VAG1416.

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

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

-- Remove the nuts -B- for the output shaft bearing support.

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

-- Remove the differential.