Transmission Housing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Driving Sleeve VW 244 B
Transmission Support VW 353
Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 407
Tube 37 mm Dia.VW 416 B
Guide Piece VW 436 A
Guide Pin VW 439
Slide Hammer-Complete Set VW 771
Holding Fixture VW 801
Guide Piece 10-15
Thrust Pad 3124
Bearing Driver 3264
Subframe Support Assm. Device 3290
Torque Wrench (5-50 Nm) V.A.G 1331
Drift T10168
Drift T10169 or T10362
Thrust Piece T10203
Kukko Extractor 14.5-18.5 mm 21/2
Kukko Extractor 23.5-30 mm 21/4
Kukko Support 22/2
Threaded Adapter from Kukko Support 22/1

Fig 1: Identifying Screwdriver To Knock Through Rubber At Center Of Sealing Cap

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-- Pierce the center of the rubber cover -A- with a screwdriver -B- and pry out the cover in the -direction of arrow-.

Fig 2: Drive In Cap Until Stop

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Fig 3: Identifying Lock Elbow For Selector Shaft, Removal

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-- Break off the bracket in its unlocked position.

-- Insert a screwdriver -A- into the hole in the locking bracket -B-.

-- Pry out the locking pin in the -direction of the arrow-.

Fig 4: Identifying Installation Position Of Lock Elbow

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The mark on the locking pin -arrow- must point toward the connection on the clutch slave cylinder -1-.
Dimension -a- must be approximately 45°.

Fig 5: Drive Lock Bracket For Selector Shaft In Up To Tool Stop

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NOTE: The locking pin -arrow- must be unlocked when being installed.

Fig 6: Identifying Tool Assembly To Pull Out Bearing Bushing For Selector Rod

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A -

Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm 21/2

B -

Counter support, for example, Kukko support 22/2

Fig 7: Driving In Bearing Bushing For Shift Rod To Tool Stop

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Fig 8: Identifying Press Lock Sleeve Off With Transmission Removed

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-- Place the transmission housing on the thrust plates VW 401 and VW 402 without damaging the alignment sleeves in the transmission housing.

Fig 9: Driving Off Lock Sleeve With Non-Disassembled Transmission

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Locking pin and selector shaft removed.

-- Turn the transmission so that the retaining sleeve cannot fall into the transmission.

Fig 10: Identifying Lock Sleeve Differentiation

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The following lock sleeves may be installed:

Lock sleeve with a shoulder -arrow 1-, refer to Fig 11.

Lock sleeve without a shoulder -arrow 2-, refer to Fig 12.

Allocate the components.

Fig 11: Drive In Lock Sleeve With Shoulder As Far As Stop On Tool

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The transmission housing is bolted to the clutch housing.

Fig 12: Drive In Lock Sleeve Without Shoulder As Far As Stop On Tool

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The transmission housing is bolted to the clutch housing.

Fig 13: Identifying Tool Assembly To Pull Out Needle Bearing For Reverse Shaft Of Transmission Housing

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A -

Internal puller 23.5 to 30 mm, for example, Kukko extractor 23.5-30 mm 21/4

B -

Counter support, for example, Kukko support 22/2

NOTE: The needle sleeve will be damaged when it is removed and must be replaced.

Fig 14: Driving In Needle Sleeve For Reverse Shaft Into Transmission Housing

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-- Lay the reverse shaft thrust washer -B- on the needle sleeve -A- while pressing it in.

-- Support the transmission housing beneath the bearing mount using the tube 37 mm dia. VW 416 B.

Fig 15: Identifying Selector Shaft Bushing, Removal

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-- Use the threaded adapter from the Kukko support 22/1 -arrow-.

-- Hold the spindle on the subframe support assm. device 3290 steady and turn the nut -B-.

A -

Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm 21/2

Fig 16: Driving Bearing Bushing For Selector Shaft As Far As Tool Stop

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Fig 17: Driving Out Sealing Plugs

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-- Remove the plug -1- from the inside of the transmission housing to the outside.

Fig 18: Driving In Sealing Plug

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-- Install the plug -1- approximately 3 mm under the upper edge of the housing -a- using the bearing driver 3264.