Transmission Without Cap/Input Shaft Retaining Ring Assembly Sequence

Fig 1: Identifying Transmission Housing Without Sealing Cap Circlip

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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-.

NOTE:

If one of the fastening holes does not contact the Transmission Support, place shims between fastening hole and Transmission Support.

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

Fig 2: Identifying Transmission Secured To Assembly Stand With Bolts

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-- Place drip tray underneath.

-- Drain gear oil.

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

Fig 3: Identifying Slave Cylinder With Release Bearing

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

Fig 4: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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-- 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 flanged shaft and stub shaft.

As of transmission build date 01 11 4, the right stub shaft was replaced by a flange shaft.

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

Fig 5: Identifying Interior Clutch Housing Bolts

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NOTE:

One bolt -arrow- is located outside of bolting flange.

-- 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.

Fig 6: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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

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

Fig 7: Identifying Support, Internal Puller & Cap

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-- 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:

Fig 8: Identifying Screwdrivers & VW 309 To Remove Circlip From Grooved Ball Bearing Of Input Shaft/Transmission Housing

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-- 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.

-- If present, remove washer -1- from transmission housing -2-.

Fig 9: Identifying Laying Washer Above Grooved Ball Bearing

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If transmission is replaced, check whether washer must be reinstalled. TRANSMISSION WITHOUT CAP/INPUT SHAFT RETAINING RING ASSEMBLY SEQUENCE

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

Fig 10: Identifying Transmission Housing To Clutch Housing Bolts

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

Fig 11: Identifying Adapter VW 771/40 Installed Into Threaded Hole Of Transmission Housing

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-- 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-.

NOTE:

If necessary, carefully pry up all around and alternating between sides on protruding flange taking care not to damage sealing surfaces.

-- If present, remove washer -1- from grooved ball bearing -2-.

Fig 12: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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-- If transmission is replaced, check whether washer must be reinstalled. TRANSMISSION WITHOUT CAP/INPUT SHAFT RETAINING RING ASSEMBLY SEQUENCE

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

Fig 13: Identifying Separating Tool And Thrust Tube Removed From Input Shaft

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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-.

Fig 14: Identifying Differential & Output Shaft Lifted With Selector Rods

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-- 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-.

NOTE:

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

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

NOTE:

Grooved ball bearing on input shaft must always be replaced INPUT SHAFT ASSEMBLY OVERVIEW => List Item:Input Shaft .

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-.

Fig 15: Identifying Input Shaft And Output Shaft For 5th/6th Gears Inserted Together With Selector Rod, Shift Fork And Reverse Shaft

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-- Then insert differential -1-.

Fig 16: Identifying Differential, Input Shaft & Output Shaft

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NOTE:

A 2nd technician is required for further installation of shafts into clutch housing.

-- 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.

Fig 17: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE:

For the sake of illustration, clutch housing is depicted rotated 180°.

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

From transmission build date 4.10.06 through approximately 1.21.08

One washer each is inserted above and below input shaft grooved ball bearing.INPUT SHAFT ASSEMBLY OVERVIEW => List Item:Input Shaft

Upper washer	Outer diameter	78.6 mm
Lower washer	Outer diameter	85 mm

-- Check transmission housing.

-- Measure shoulder above grooved ball bearing mount.

Fig 18: Identifying Measurement Of Shoulder Above Grooved Ball Bearing Mount

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Above the bearing seat	Dimension "a"	Washer
Through transmission build date 09 04 6	10 mm	No
From transmission build date 10 04 6	10.7 mm	Yes

Fig 19: Identifying Bearing Seat

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Area below the bearing seat		Washer
Through transmission build date 09 04 6	Not deeper.	No
From transmission build date 10 04 6	Slightly deeper.	Yes

Fig 20: Identifying Alignment / Placement Of Washer On Grooved Ball Bearing

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Check the transmission housing and grooved ball bearing.

Fig 21: Flattened Areas On Grooved Ball Bearing And Bearing Seat In Transmission Housing, Approximately From Transmission Build Date 21 February 2008

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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 washers 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.

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

Apply Sealing Paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

Align the marking on the grooved ball bearing -A- with the marking on the transmission housing -B- and mount the transmission housing.

Fig 22: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

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

Fig 23: Allocation Of Bolts As Replacement Parts

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Allocation of bolts:

A - Bolt with permanent washer

B - Bolt without washer

C - Bolt with permanent washer

Fig 24: Identifying Laying Washer Above Grooved Ball Bearing

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See if a washer -1- must be placed above the grooved ball bearing -2-. Refer to GROOVED BALL BEARING CHANGES

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

Fig 25: Identifying Circlip & Special Tool VW 309

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

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

Fig 26: Identifying Selector Shaft Inserted Into Lower Bearing And Into Shift Forks

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NOTE:

To improve clarity, the cap is removed.

-- 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.

Fig 27: Identifying Selector Shaft Pressed Against Lock Sleeve And Guided Downward With Shift Finger

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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).

NOTE:

If shift cover stands at an angle to bolting surface, selector shaft is not inserted in lower bearing.

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

Fig 28: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft

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

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

-- Install flanged shaft and stub shaft with compression springs, thrust washers and tapered rings.

As of transmission build date 01 11 4, the right stub shaft was replaced by a flange shaft.

-- Drive input shaft seal in flush.

Fig 29: Driving In Input Shaft Oil Seal Flush

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-- Install slave cylinder with release bearing CLUTCH SLAVE CYLINDER WITH RELEASE BEARING .

-- Shift through all gears.

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

Fig 30: Driving Cap Into Transmission Housing To Stop Of Thrust Piece T10042

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