5TH Gear And Transmission Housing Cover: Notes
If only the 5th has to be removed, follow this procedure:
If it is necessary to remove the transmission housing, follow the transmission disassembly and assembly procedure, refer to TRANSMISSION .
Special tools and workshop equipment required
- Holding Plate VW309
- Transmission Support VW353
- Needle Bearing Drift VW295
- Driving Sleeve VW244 B
- Hot Air Blower VAG1416
- Torque Wrench 1331 5-50Nm VAG1331
- Bracket - Multiple Use 30-211A
- Driving Sleeve 32-111
- Thrust Piece T10030/4 from Assembly Tool T10030
- Tube 37 mm Dia.VW416 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. 8/65VW433
- Torque Wrench 1332 40-200Nm VAG1332
Procedure
-- 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 transmission support VW353, install the following special tools for support:
Under the Input Shaft:
- Bracket - Multiple Use 30 - 211 A
- Driving Sleeve 32-111
- Thrust Piece T10030/4
- The input shaft may be supported by 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. 8/65VW433
-- Secure the transmission to the transmission support VW353.
-- Remove the transmission housing cover -arrow- .
-- Make sure the puller legs T10040/2A can be installed correctly under the 5th gear.
| The puller legs T10040/2A cannot be installed correctly. | |||
|---|---|---|---|
-A- puller legs T10040/2A prematurely touch the:
|
"Combined removal" of the: "5th gear synchronizer hub" , " 5th gear" and the "transmission housing" , refer to TRANSMISSION . | ||
| -B- puller legs T10040/2A touch the ribs in the transmission housing under the 5th gear | |||
| The puller legs T10040/2A can be installed correctly. | |||
|---|---|---|---|
| The 5th gear can be removed individually, refer to Fig 5. |
-- Cover the openings in the transmission housing 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 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- then remove the bolts -A- for the synchronizer hub and 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 any locking compound residue still in the threaded holes using a thread tap if the shafts are not going to be replaced.
Remove the 5th gear synchronizer hub together with the locking collar and locking pieces. Use the puller T10309.
-- Insert the shell T10309/1 between the 5th gear -A- and the mount for the 5th gear selector fork -B- .
- The shell T10309/1 must be placed under the synchronizer ring.
-- Press the puller into the end position, if necessary.
-- Rotate the shell T10309/1 to the opposite side in the -direction of the arrow- .
-- Insert the threaded insert T10309/3 into the shell T10309/1.
-- Install the second shell T10309/1 and mount the tube T10309/2 on the tool.
-- Check synchronizer hub for damage after pulling.
-- Replace the 5th gear synchronizer ring
-- Remove the 5th gear selector gear with needle bearing.
-- Remove the 5th gear.
-- Insert the puller leg -A- .
B - Thrust piece T10040/3 or a 17 mm M10 x 20 bolt
When removing the gear, make sure the puller leg does not bend outward. Check the 5th gear for damage.
Heat the gear with the Hot Air Blower VAG1416.
Remove the 5th gear and transmission housing cover as follows:
- Make sure the Bracket - Multiple Use 30-211A and the Support Bridge T10323 are installed.
-- Secure the bolt on the Bracket - Multiple Use 30-211A with the nut -A- .
Installed Position, 5th Gear
The groove all the way around -arrow- faces the transmission housing.
-- Warm the 5th gear wheel to approximately 100°C using Inductive Heater VAS6414.
Wear safety gloves.
-- Install the 5th gear.
Checking 5th gear synchronizer ring.
-- Before reinstalling drive gear and synchronizer ring for 5th gear, press the synchronizer ring onto the taper of the drive gear and measure the gap dimension -a- using a feeler gauge.
| Gap Dimension -a- | Installation Dimension | Wear limit |
|---|---|---|
| 5th Gear | 1.1 to 1.7 mm | 0.5 mm |
-- Install 5th gear selector gear with needle bearing.
-- Place the 5th gear synchronizer ring onto the selector gear.
-- If disassembled, assemble the 5th gear locking collar/synchronizer hub Figure.
Installed position of 5th gear synchronizer hub/locking collar
The pointed teeth on the locking collar -arrow 1- and the high collar on the synchronizer hub -arrow 2- face the transmission housing.
The notches -arrow 3- on the synchronizer hub must line up with the cast locking pieces on the synchronizer ring (→ lower illustration).
5th gear synchronizer ring with cast locking pieces -arrows- .
-- Cover all openings with a cloth to prevent foreign objects from getting into the transmission.
-- Warm the 5th gear synchronizer hub to approximately 100 °C using Hot Air Blower VAG1416.
Wear safety gloves.
-- Install the 5th gear synchronizer hub
Make sure there is enough clearance when installing the synchronizer ring.
-- Loosen the support for the input shaft.
-- If it has not been done already, clean any locking fluid residue from the threaded hole for the synchronizer hub bolt and 5th gear with a thread tap.
Otherwise, there is the danger that the screws could shear off.
-- Screw-in new synchronizer hub bolts and 5th gear.
Installed position of plate springs for 5th gear synchronizer hub and drive gear securing bolts
The outer diameter -arrows- faces 5th gear.
-- Engage 5th gear -arrow 1- and 1st gear -arrows 2- and -3- and then tighten the bolts -A- for the synchronizer hub and the 5th gear to the tightening specification, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR OVERVIEW .
-- 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 be loosened now.
-- Install the 5th gear shift fork.
Adjusting the 5th gear
-- Engage 5th gear. Loosen the bolt -1- . Push the locking collar and the shift jaw in -direction of arrow- . Tighten the bolt -1- to the tightening specification.
- Check measurement: it must not be possible to slide a 0.2 mm feeler gauge between the locking collar and drive gear. Repeat the adjusting procedure if necessary.
-- Remove 5th gear. The locking collar must be in the neutral position. The synchronizer ring must move freely.
-- Move the shift lever (selector lever) through all the gears.
-- Install the transmission housing cover and tighten the bolts to specification, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR OVERVIEW .
-- Install the clutch release lever and release bearing, refer to CLUTCH RELEASE MECHANISM OVERVIEW .
-- Fill the transmission fluid, refer to Transmission Fluid, Checking and Filling .