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From Build Date, 19 May 2003


Transmission Disassembly and Assembly From Build Date, 19 May 2003


Special tool and workshop equipment required:
- Holding Plate -VW 309-
- Holding Fixture -VW 313-
- Transmission Support -VW 353-
- Thrust Tube -VW 455-
- Slide Hammer -Complete Set- -VW 771-
- Sleeve -30-21-
- Bracket -30-211A-
- Thrust Piece -T10042-
- Drift -T10168-
- Thrust Piece -T40008-
- Torque Wrench (5-50 Nm) -V.A.G 1331-
- Hot Air Blower -V.A.G 1416-
- Kukko Puller 12-14.5 mm -21/1-
- Kukko Separating Tool 5-60 mm -17/0-
- Kukko Support -22/1-

Disassembling






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

- Turn the transmission in the assembly stand so that the drain plug is facing down.

- Place a drip tray underneath.

- Drain the transmission fluid from the transmission and bevel box.





- Remove the right flange shaft bolt using the -V.A.G 1669- or a 6 mm socket.

NOTE:
The right flange shaft stays in the bevel box.






- Remove the four bevel box to transmission bolts -arrows- (only three are shown in the illustration).

- Remove the bevel box from the transmission.

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






Make sure the shift unit is not blocked by the lock elbow -arrow-.

- Move the shift unit into neutral.
- Remove the locking screw -2-.
- Remove the bolts -3-.
- Remove the shift unit -4 from the transmission housing.
- Remove the flange shaft and the stub shaft.






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

NOTE:
One bolt -arrow is located outside of the bolting flange.






- Secure the input shaft by inserting the -VW 455- over the input shaft, onto the clutch housing.

- Tension the separating tool -A-, for example, -17/0-, tightly behind the input shaft splines.

The back of the separating tool must contact the pressing sleeve and must be free of play.






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

- Remove the cover from the transmission housing.

A - Counter support, for example, -22/1-

B - Internal puller 8 to 12 mm for example, -21/01-.






Remove the lock ring -C- from the grooved ball bearing on the input shaft/ transmission housing as follows:
- Hold one end of the locking ring secure using a screwdriver -A-.
- Pry the other end out of the groove in the grooved ball bearing in the -direction of arrow- using a screwdriver -B-.






- Remove the washer -1- from the transmission housing -2-, if equipped.
- If transmission is replaced, check whether the washer must be reinstalled.






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






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

- 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 -V.A.G 1416-.

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

NOTE:
If necessary, carefully pry up all around and alternate between sides on the protruding flange. Be careful not to damage the sealing surfaces.






- Remove the washer -1- from the grooved ball bearing -2-, if equipped.

- If the transmission is being replaced, check whether the washer must be reinstalled.






- Remove the separating tool -A- and the -VW 455- from the input shaft.

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, left the output shaft for 1st to 4th gear together with the selector forks -2- -arrow A-.

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

NOTE:
If necessary, the differential can be shifted again in the clutch housing after lifting the shafts.

- Remove the input shaft seal using the -30-21-.

NOTE:
Always replace the grooved ball bearing -item 6-.

Assembling

- Press the new grooved ball bearing -item 6- on the input shaft.






- Install the input shaft -1-, output shaft 5th/6th gear -2- together with the selector shaft -3-, the selector fork -4- and the reverse gear shaft -5-.






- Install the differential -1-.

NOTE:
A 2nd technician is needed to help install the shafts into the clutch housing.

- Hold the output shaft for 1st through 4th gear -3- and the selector forks -4- with the right hand.

- Slightly lift the differential with the left hand.

- Have the second technician lift the input shaft, the 5th/6th gear output shaft and reverse gear -2- together with the reverse gear shaft slightly at the same time.

- Install the 1st to 4th gear output shaft in the -direction of the arrow-.

- The input shaft, output shafts and final drive gear/ differential must engage.

- Together with a second technician, place shafts and differential in their bearing seats.






- Secure the -30-211A- for the input shaft to the clutch housing.

NOTE:
The clutch housing is shown in the illustration rotated 180°.

- Install the bolt -A- just far enough until the input shaft starts to lift.

Transmission Housing Changed from Build Date 10 April 2006
One washer each is inserted above and below the input shaft grooved ball bearing -item 6-






Upper washer
Outer Diameter 78.6mm
Lower washer
Outer Diameter 85mm


- Check the transmission housing.

- Measure the shoulder above the grooved ball bearing mount.





The shoulder is deeper than the washer mount.
Shoulder above grooved ball bearing Dimension "a" Washer
From build date 10 April 2006 --> 10.7mm yes
Through build date 09 April 2006 --> 10mm no



Bearing Seat for Grooved Ball Bearing in Transmission Housing Changed from Build Date 10 April 2006






Bearing seat -arrow- for the grooved ball bearing (-2- ->lower illustration) is slightly lower than the washer mount (-1- ->lower illustration).

From Build Date 10 April 2006, place a washer (outer diameter = 85 mm) -1- on the grooved ball bearing -2-.






- Heat the transmission housing using a heat gun, for example, -V.A.G 1416- in the area of the bearing seat for the grooved bearing/ input shaft to 100°C (212°F) for approximately 10 minutes.






- Install the transmission housing and tighten the bolts -A, B, and C- to specifications.

If the steel bolts (outer hex head) are the replacement part, pay attention to the allocation:
A - Bolt with a permanent washer
B - Bolt without a washer
C - Bolt with a permanent washer

From Build Date 10 April 2006, install a washer -1- (outer diameter = 78.6 mm) above the grooved ball bearing -2-.










- Install the grooved ball bearing/ input shaft lock ring -1-.

- Remove the -30-211A- for the input shaft.






- If the shift unit retaining sleeve has been removed, install it now all the way in using the -T10168-.

- Turn the transmission with the opening for the shift unit in the assembly stand upward.






- Install the shift unit -1- into the lower bearing -2- and into the selector forks -3-. The cap is not shown in the illustration.






- Push the shift unit -1- against the retaining sleeve -2- in the -direction of arrow- and guide it through the selector fork all the way down using the shift finger -3-.
- The shift unit cover -4- must be parallel to the bolting surface on the transmission housing.
- It must be possible to move the shift unit shaft easily (forward and backward).

NOTE:
If the shift unit cover is at an angle to the bolting surface, then the shift unit is not installed into the lower bearing.






- Tighten the bolts -3- for the shift unit cover -4-.

- Install the locking screw -2-, lock elbow -arrow- must not be installed when doing so.

- Install the backup lamp switch -F4- -1-.

- Install the flange shaft and stub shaft, the pressure springs, the thrust washers and the tapered rings.






- Install the Input shaft seal so that it is flush using the -T40008-.

- Install the clutch slave cylinder with release bearing.

- Move the shift lever through all the gears.






- Drive the cap into the transmission housing until seated using the -T10042-

Install the bevel box to the transmission as follows:






- Always replace the O-ring for sealing the bevel box to the transmission -arrow A- and the O-rings for sealing the sleeves -arrows B and C-. Lubricate the O-rings lightly with oil.
- Slide the bevel box completely on the transmission, while doing this, join the splines of the input shaft/ bevel box centrally with the connecting sleeve/ differential.
- Bring the right drive axle splines and the differential bevel gear into alignment. Rotate the flange shaft if necessary.
- With proper tooth position and central guiding, the bevel box slips up to the stop against the transmission.

NOTE:
Do not pull the bevel box against the transmission, otherwise the bevel box is tilted and the mounting eyelets can break off.






- Tighten the 4 bevel box bolts -arrows0 (only 3 are shown in illustration) to the transmission.

- Tighten the bolt on the right flange shaft using the -V.A.G 1669- or a 6 mm socket while counter holding the flange shaft with a drift.
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