Transmission Housing, Servicing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Bearing Driver - Multiple Use: VW244B
Transmission Support: VW353
Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW407
Press Piece - 37mm: VW416B
Guide Pin: VW436A
Press Piece - Guide Pin: VW439
Slide Hammer Set: VW771
Crankshaft Holding Fixture: VW801
Guide Pin: 10-15
Press Piece - Pivot Mount Bushing: 3124
Bearing Installer - Crankshaft Pilot Bearing: 3264
Subframe Support Tool: 3290
Torque Wrench, 6-50Nm: VAG1331A
Bushing Driver - Selector Shaft: T10168
Locking Sleeve Drift: T10169 or Locking Sleeve Drift: T10362 . Refer to Fig 10.
Breather Tube Tool: T10203
-1- Internal Puller: VAS251605 (Kukko 21-2)
-1- Internal Puller: VAS251609 (Kukko 21-4)
-4- Counter Support: VAS251623 (Kukko 22/2)
Thread adapter from Counter Support: VAS251621 (Kukko 22-1)

Cap A, Removing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Install the Cap Until it Stops.

Fig 2: Drive In Cap Until Stop

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Gearshift Shaft Locking Elbow, Removing

Fig 3: Identifying Lock Elbow For Selector Shaft, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Break off the bracket in its unlocked position.

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

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

Locking Elbow Installation Position

Fig 4: Identifying Installation Position Of Lock Elbow

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Install the Gearshift Shaft Locking Elbow arrow All the Way Up to the Tool

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The locking elbow must be unlocked when being installed.

Shift Rod Bearing Bushing, Removing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Internal Puller: VAS251605 (Kukko 21-2)

B - Counter Support: VAS251623 (Kukko 22/2)

Install the Gearshift Rod Bearing Bushing All the Way up to the Tool

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Remove the Retaining Sleeve A from the Transmission Housing

Fig 8: Identifying Press Lock Sleeve Off With Transmission Removed

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the transmission housing on the : VW401 and : VW402 so that the alignment sleeves in the transmission housing do not get damaged.

Use the 10-15 to Remove the Retaining Sleeve with the Transmission Assembled

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Locking bolt and gearshift shaft removed.

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

Retaining Sleeve Differentiation

Fig 10: Identifying Lock Sleeve Differentiation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The following retaining sleeves may be installed:

Retaining sleeve with a shoulder -arrow 1-. Refer to Fig 11.

Retaining sleeve without a shoulder -arrow 2-. Refer to Fig 12.

Drive in Lock Sleeve with Shoulder as Far as Stop on Tool

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The transmission housing is bolted to the clutch housing.

Drive in Lock Sleeve without Shoulder as Far as Stop on Tool

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The transmission housing is bolted to the clutch housing.

Remove the Reverse Shaft Needle Sleeve from the Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Internal Puller: VAS251609 (Kukko 21-4)

B - Counter Support: VAS251623 (Kukko 22/2)

NOTE:

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

Needle Sleeve A, Installing in Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Support the transmission housing with the : VW416B directly under the bearing mount.

Gearshift Shaft Bearing Bushing, Removing

Fig 15: Identifying Selector Shaft Bushing, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the thread adapter from : VAS251621 -arrow-.

-- Hold the spindle on the : 3290 steady and turn the nut -B-.

A - : VAS251605 (Kukko 21-2)

Install the Gearshift Shaft Bearing Bushing A up to the Tool Stop

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Plug 1, Removing

Fig 17: Driving Out Sealing Plugs

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Plug 1, Installing

Fig 18: Driving In Sealing Plug

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Using the : 3264 , drive in the plugs to dimension -a- approximately 3 mm below the upper edge of the housing.