Case: Service and Repair

Special tools, testers and auxiliary items required:
^ Multi-purpose tool 771/1 with attachment 771/15
^ Mandre l2062
^ Press tool VW408A
^ Tube VW423
^ Thrust pad VW454
^ Extractor lever VW681
^ Guide pin 10-15
^ Drift sleeve 30-100
^ Mandre l30-505
^ Installing tool 40-503
^ Internal puller 14.5-18.5 mm e.g. Kukko 21/2
^ Internal puller 30-37 mm e.g. Kukko 21/5
^ Depth gauge
^ Assembly sleeve, Part No. 01 E311120

Notes:
^ Adjustments are required when replacing components marked 1).





1. Seal
^ For drive flange
^ Pulling out see Fig. 1
^ Driving in see Fig. 2
^ Fill space between sealing lips with sealing grease G52 128 A1.
^ Replacing with transmission installed
2. Final drive cover 1)
3. O-ring
^ For cover for final drive
^ Replace
4. Shim "S1"
^ Note thickness
^ Adjustment overview
5. Outer race for large taper roller bearing 1)
^ For differential
^ Driving out and driving in
6. Outer race for small taper roller bearing 1)
^ For differential
^ Driving out and driving in
7. Shim "S2"
^ Note thickness
^ Adjustment overview
8. Seal
^ For input shaft
^ Levering out see Fig. 3
^ Driving in see Fig. 5
^ Always replace when removing input shaft
^ Replacing when transmission is not disassembled see Fig. 4 and Fig. see 5
9. Oil drain plug, 40 Nm
10. Ball sleeve
^ For selector shaft
^ Replace
^ Pulling out see Fig. 6
^ Driving in see Fig. 7
11. Ball sleeves
^ For selector shafts
^ Replace
^ Pulling out see Fig. 6
^ Driving in see Fig. 7
12. Circlip
^ Installation position: eyes facing up
13. Switch for reversing lights, 20 Nm
14. O-ring
^ For cover for selector shaft
^ Replace
15. Cover for selector shaft
^ Removing
^ Installing
16. Ball stud, 20 Nm
^ For connecting rod
17. Outer race for large taper roller bearing 1)
^ For drive pinion
^ Pulling out
^ Pressing in
18. Circlip
^ Removing see Fig. 16
19. Shim "S3"
^ Note thickness
^ Adjustment overview
20. Needle bearing
^ For input shaft
^ Pulling out see Fig. 13
^ Driving in see Fig. 14
^ Measuring insertion depth see Fig. 15
21. Locking bolt
^ For selector shaft
^ Removing
^ Installing
^ Tightening torques: -or aluminum bolt = 50 Nm, and for steel bolt = 70 Nm
22. Stud, 40 Nm
^ For pushrod
^ No longer installed m.y. 1999
23. Breather
^ Clip cap on
^ For transmission with sleeve
^ Insertion depth of sleeve see Fig. 11
^ For transmission with with additional breather hose see Fig. 12
24. Seal for selector shaft
^ Can be replaced when transmission is removed but not dismantled
^ Replace
^ Pulling out see Fig. 8
^ Driving in see Fig. 9
^ Always use assembly sleeve for installing see Fig. 10
25. Transmission - housing 1)
^ With oil baffle plate for transmission with transmission oil cooler
^ Installation position of oil baffle plate see Fig. 17
26. Magnet
^ Clean
^ When replacing transmission housing drive in with e.g. press tool VW 408 A
27. Sender for - speedometer -G22
^ Replacing
28. O-ring
^ Replace
29. Oil filler plug, 40 Nm





Fig. 1 Pulling out seal for drive flange

Notes:
^ Illustrated, removing oil seal on right hand side.
^ Procedure for removing oil seal on left and right-hand sides is identical.





Fig. 2 Driving in seal for drive flange
- Fill space between sealing lip and dust lip with sealing grease G52 128 A1.
^ Pressing-in depth (factory): 5.5 mm
^ Pressing-in depth when re-installing a used drive flange (repairs): 6.5 mm

Notes:
^ Illustrated, installing oil seal on right hand side.
^ Procedure for installing oil seal on left and right-hand sides is identical.





Fig. 3 Levering out seal for input shaft when transmission is dismantled
- Lever out seal carefully with VW 681.





Fig. 4 Removing seal for input shaft when transmission is not dismantled
- Lever out seal carefully with a screwdriver.

Note: Do not damage bearing surface on input shaft for shaft seal.





Fig. 5 Driving in seal for input shaft
- Fill space between sealing lip and dust lip of new seal for input shaft with sealing grease G52 128 A1.
- Fit a thin protective hose tightly over splines of input shaft.
- Drive in seal for input shaft.
^ Pressing-in depth (factory): 3.5 mm
^ Pressing-in depth when re-installing a used input shaft (repairs): 4.5 mm
- Remove protective hose.





Fig. 6 Pulling out ball sleeve
- Remove circlip.
A- Internal puller 14.5-18.5 mm, e.g. Kukko 21/2





Fig. 7 Driving in ball sleeve
- Drive in onto stop.





Fig. 8 Pulling out seal for selector shaft

Note: With transmission removed but not dismantled, carefully lever out seal without damaging the shaft with a screwdriver.





Fig. 9 Driving in seal for selector shaft
Selector shaft installed or removed
- Fill space between sealing lip and dust lip with sealing grease G52 128 A1.
- Pull assembly sleeve onto selector shaft see Fig. 10.
- Drive seal into housing onto stop.





Fig. 10 Installing seal and selector shaft with assembly sleeve
- To avoid damaging the seal -C- always use assembly sleeve -A-, Part No. 01 E 311 120, to install seal or selector shaft.





Fig. 11 Insertion depth of breather sleeve for transmissions without breather hose
^ Dimension a = 21 mm





Fig. 12 Breather for transmission with breather hose
1. Transmission
2. Sleeve: drive in onto stop
3. Pipe: drive in onto stop
4. Clamp
5. Hose
6. Breather pipe
7. Retaining clip





Fig. 13 Pulling needle bearing out of transmission housing
A - Internal puller 30-37 mm, e.g. Kukko 21/5





Fig. 14 Driving needle bearing into transmission housing
^ Installation position: inscription on bearing faces tool
^ Insertion depth see Fig. 15





Fig. 15 Insertion depth of needle bearing
Dimension a = 105 mm





Fig. 16 Removing circlip
- Lift circlip out of the groove by turning one end of the circlip with a screwdriver -A-.
- Secure this end with a screwdriver -B-.
- Lever circlip out further by repositioning screwdriver -A-.





Fig. 17 Installation position of oil baffle plate only for transmission with transmission oil cooler
1. Breather
2. Oil baffle plate
3. Selector shaft

Selector shaft (complete), disassembling and assembling





1. Selector cylinder
2. Roll pin
^ Drive out and drive in flush Fig. 1
3. Selector shaft
^ Driving out see Fig. 2
^ Driving in see Fig. 3
^ Installation position: flat (arrow) and selector finger -4- face in same direction
4. Selector finger
^ Observe installation position to 3
5. Cam for reversing light switch





Fig. 1 Driving out and driving in roll pin flush
A - Drift
B - Vice clamps





Fig. 2 Driving out selector shaft
A - Drift
B - Vice clamps





Fig. 3 Driving in selector shaft
A - Wooden block

Notes:
^ Bring holes into alignment.
^ Flat on selector shaft and selector finger point in same direction.