Disassembling the Transmission

Fig 1: Identifying Transmission Secured To Assembly Stand With Bolts

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-- Attach the transmission to the assembly stand with the bolts -arrows-.

-- Turn the transmission in the assembly stand, until the oil drain plug faces down.

-- Place a drip Drip Tray for VAS 6100 VAS 6208.

-- Drain the transmission fluid.

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

Fig 2: Identifying Slave Cylinder With Release Bearing

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Make sure the gear shift shaft is not locked by the locking pin -arrow-.

Fig 3: Identifying Back-Up Lamp Switch, Mounting Screw, Bolts & Selector Shaft

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-- Move the gear shift shaft into neutral.

-- Remove the Backup Lamp Switch -F4- -1-.

-- Remove the locking bolt -2-.

-- Then, remove the bolts -3-.

-- Remove the gear shift shaft with shift cover -4- from the transmission housing.

NOTE: Use the Pry Lever 80 - 200 to press against the spring force of the securing bushing -direction of arrow- so that the gear shift shaft -1- does not touch the securing bushing -2- when removing.

Fig 4: Securing Bushing

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-- Remove the left and right flange shaft bolts. To do this, install two bolts into the flange and counter hold the flange shaft using a pry bar.

Fig 5: Identifying Flange Shaft

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-- Remove the flange shafts and the pressure springs.

-- Remove the bolts -B- that connect the clutch housing to the transmission housing.

Fig 6: Identifying Interior Clutch Housing Bolts

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-- Lock the input shaft as follows:

The stub shaft splines on the input shaft has different lengths on the transmission.

-- Either place the Press Piece - Multiple Use VW 455 over the input shaft on the clutch housing.

Fig 7: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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-- Or place the Press Piece - Front Wishbone 3160 over the input shaft on the clutch housing.

Fig 8: Identifying Separating Tool And Sleeve 3160

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

The back of the separating tool must touch the Press Piece - Multiple Use VW 455 or the Press Piece - Front Wishbone 3160 without any free play.

Metal Sealing Cap

Fig 9: Identifying Transmission Housing Without Sealing Cap Circlip

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-- Remove the sealing cap/input shaft circlip -A-.

-- Pierce the rubber piece in the center of the sealing cap -C- using a screwdriver.

Fig 10: Identifying Support, Internal Puller & Cap

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-- Remove the sealing cap -C- from the transmission housing.

A -

Counter support, for example, Kukko support 22/1

B -

Internal puller 8 to 12 mm, for example, Kukko puller 12-14.5 mm 21/1

NOTE: Push through the center of the sealing cap using a screwdriver -2- to remove the sealing cap -1-

Fig 11: Prying The Cover Out

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Carefully pry the sealing cap -1-, using a screwdriver -2-, off the transmission housing.

Plastic Sealing Cap

Fig 12: Identifying Screwdriver To Remove Tabs

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Carefully remove all tabs -A-. Do not damage the transmission housing when doing so.

-- Pry out the sealing cap.

Fig 13: Identifying Screwdriver To Pry Out Sealing Cap

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• Make sure the individual parts of the cover are removed, if necessary.

Continuation for All: 

Remove the locking ring -C- from the grooved ball bearing on the input shaft/transmission housing as follows:

Fig 14: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

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

-- Pry the other end out of the groove in the grooved ball bearing in the -direction of the arrow- using the a screwdriver -B-.

-- Pry out the rest of the locking ring using the screwdriver -B-.

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

Fig 15: Identifying Transmission Housing To Clutch Housing Bolts

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-- Install the adapter VW 771/40 into the threaded hole in the transmission housing.

Fig 16: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

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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, inductive heat unit V.A.G 1416.

-- Remove the transmission housing from the clutch housing in the -direction of the arrow- using the slide hammer VW 771/1.

-- Remove the separating tool -A- and the Press Piece - Multiple Use VW 455 or the Press Piece - Front Wishbone 3160 from the input shaft.

Fig 17: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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A second technician is needed to help remove the shafts from the clutch housing.

-- Lift the differential -1- with the left hand. With the right hand, lift the output shaft for 1st to 4th gear together with the selector shafts with selector forks -2- -arrow A-.

Fig 18: Identifying Differential & Output Shaft Lifted With Selector Rods

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-- At the same time, the 2nd technician lifts the input, reverse and output shaft for 5th/6th gear and reverse gear -3- together with the selector shafts with selector forks out of the clutch housing -arrow B-

-- Remove the input shaft seal.