Transmission With Retaining Ring For Cover/Input Shaft, Assembly Sequence

Special tools and workshop equipment required 

• Holding Plate VW 309
• Holding Fixture VW 313
• Transmission Support VW 353
• Pressing Sleeve VW 455
• Slide Hammer VW 771
• Internal Puller Kukko 21/01
• Separating Tool Kukko 17/0
• Counter-Support Kukko 22/1
• Bracket 30-211A
• Thrust Piece T10042
• Thrust Piece T40008
• Torque Wrench V.A.G 1331
• Heat Gun V.A.G 1416
• Drift T10169
• or Drift T10362, refer to Figure

Removing 

-- Secure transmission to assembly stand with bolts -arrows-.

-- Rotate transmission in assembly stand with oil drain plug downward.

-- Place drip tray underneath.

-- Drain gear oil.

-- Remove slave cylinder with release bearing -arrows-.

In the following step, ensure selector shaft is not locked by the lock elbow -arrow-.

-- Move shift shaft to neutral position.

-- Remove mounting bolt -2-.

-- Then remove bolts -3-.

-- Remove Back-Up Light Switch -F4- -1-.

-- Pull selector shaft -4- off transmission housing.

-- Remove the flange shafts.

-- Remove bolts -B- inside clutch housing for securing clutch housing to transmission housing.

-- Secure input shaft by inserting Pressing Sleeve VW 455 over input shaft onto clutch housing.

-- Then tension Separating Tool -A-, for example Kukko 17/0 tightly behind input shaft splines.

During this, back side of Separating Tool must contact Pressing Sleeve free of play.

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

-- Knock rubber through in center of cap -C- using a Screwdriver.

-- Remove cap from transmission housing.

A - Support, for example Kukko 22/1

B - Internal Puller 8 to 12 mm, for example Kukko 21/01

Remove circlip -C- from grooved ball bearing of input shaft/transmission housing as follows:

-- Hold one end of circlip in place using Screwdriver -A-.

-- Using Screwdriver -B-, pry other end out of groove for grooved ball bearing in direction of -arrow-.

-- By repositioning Screwdriver -B-, pry the circlip out further.

-- Remove mounting bolts -A- for transmission housing at clutch housing.

-- Screw Adapter VW 771/40 into threaded hole of transmission housing.

-- Heat transmission housing using Heat Gun V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to 100 °C / 212 °F for approximately 10 minutes.

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

-- Remove Separating Tool -A- and Pressing Sleeve VW 455 from input shaft.

A 2nd technician is required to remove shafts from clutch housing.

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

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

-- Drive out sealing ring for input shaft using Sleeve 30-21.

Installing 

• A new grooved ball bearing must be pressed on to input shaft INPUT SHAFT ASSEMBLY OVERVIEW => List Item:Input Shaft .

-- First insert input shaft -1-, output shaft for 5th/6th gears -2- together with selector rod -3-, shift fork -4- and reverse shaft -5-.

-- Then insert differential -1-.

-- As shown in illustration, take output shaft for 1st to 4th gears -3- with selector rods -4- in right hand.

-- Lift differential slightly with the left hand.

-- At the same time, 2nd technician slightly lifts input shaft, output shaft for 5th/6th gears and reverse gear -2- together with reverse shaft.

-- Now, insert output shaft for 1st to 4th gears in direction of -arrow-.

• Splines of input shaft, output shafts and final drive gear/differential must engage.

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

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

-- Screw in bolt -A- far enough until input shaft rises slightly.

There is a flattened area on the grooved ball bearing and the bearing mount.

• If flattened areas -A- and -B- are present, then do not install the washer TRANSMISSION WITHOUT CAP/INPUT SHAFT RETAINING RING ASSEMBLY SEQUENCE .
• The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark the flattened side with color.

-- Place a marking on the upper area of the grooved ball bearing and on the upper area of the transmission housing bearing mount (see next illustration).

-- Heat transmission housing using Heat Gun V.A.G 1416 in area of bearing seat for grooved ball bearing/input shaft to 100 °C / 212 °F for approximately 10 minutes.

-- Install transmission housing and tighten new bolts -A-, -B- and -C- to tightening specification.

Allocation of bolts:

A - Bolt with permanent washer

B - Bolt without washer

C - Bolt with permanent washer

-- Install circlip -1- for grooved ball bearing/input shaft.

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

-- If selector shaft lock sleeve has been removed, drive it in now as far as stop on tool Figure.

-- Turn transmission with opening for selector shaft in assembly stand upward.

-- Insert selector shaft -1- into lower mounting -2- and into shift forks -3-.

-- Now press selector shaft -1- against lock sleeve -2- in direction of -arrow- and guide downward with shift finger -3- through shift forks until stop.

• Shift cover -4- must stand parallel to bolting surface on transmission housing during this.
• Selector shaft must be able to be moved easily in selector motion (up and downward).

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

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

-- Install Back-Up Light Switch -F4- -1-.

-- Install the flange shafts with the springs, thrust washers and tapered rings.

-- Drive the cap into the transmission housing as far as the stop.

-- Secure the cover and retaining ring -A- (approximately from transmission build date 21 01 8).