Transmission, Disassembling And Assembling: Notes

Special tools and workshop equipment required 

• Holding Plate :VW309A 
• or Holding Plate :VW309A 
• Holding Fixture :VW313 
• Transmission Support :VW353 
• Press Piece - Multiple Use :VW455  or Press Piece - Front Wishbone :3160 
• Slide Hammer Set :VW771 
• Slide Hammer Set - Adapter 40 :VW771/40 
• Internal Puller :VAS251603  , or for example the Internal Puller (Kukko 21/1) :VAS251601 
• Alternative to the Slide Hammer Set - Adapter 40 :VW771/40  : Stud bolt M 8 X 40 (self-made)
• Puller - Unit Injector - Adapter 3 :T10055/3 
• Bracket - Multiple Use :30-211A 
• Seal Installer - Drive Flange :T10143  or Seal Installer - Output Shaft Oil Seal :T10180 
• Locking Sleeve Drift :T10169 
• or Locking Sleeve Drift : T10362  . Refer to Figure
• Seal Installer - Drive Axle :T40008 
• Torque Wrench 1331 5-50Nm :VAG1331 
• Hot Air Blower :VAG1416 
• Pry Lever :80-200 
• Drip Tray :VAG1306 
• or Shop Crane - Drip Tray :VAS6208 
• Sealant
• Splitter :VAS251407  , or for example Splitter :Kukko 17/0 
• Counter Support :VAS251621  , or for example Counter Support :Kukko 22/1 
• Refer to the parts information for the allocation.

Mandatory Replacement Parts

• Seal - Bevel Box to Transmission

Transmission, Disassembling

-- Secure the transmission on the Transmission Support :VW353  . Refer to MANUAL TRANSMISSION, SECURING ON ENGINE AND TRANSMISSION HOLDER .

-- Place the Drip Tray underneath.

-- Drain gear oil from manual transmission.

AWD Transmission and FWD Transmission with Front Axle Differential Lock

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove right flange shaft countersunk screw with Socket.

-- Remove the four bolts -arrows- attaching the bevel box or the front axle differential lock to the manual transmission (only three bolts are shown in the illustration).

-- Carefully press bevel box or front axle differential lock off manual transmission while protecting it against falling through.

-- Note the transportation of the front axle differential lock. Refer to FRONT AXLE DIFFERENTIAL LOCK, TRANSPORTING .

FWD Transmission without Front Axle Differential Lock

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right flange shaft (the illustration shows the left flange shaft).

-- Remove the flange shaft with the pressure spring.

Continuation for All

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Transmission on vehicles with Stop/Start system: remove the Transmission Neutral Position Sensor -G701- -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Make Sure during the Following Step That the Gearshift Shaft Is Not Blocked by the Locking Elbow -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Move the gearshift shaft into neutral.

-- Remove the Back-Up Lamp Switch -F4- -1-.

-- Remove the locking bolt -2-.

-- Then remove the bolts -3-.

-- Remove selector shaft with shift cover -4- from transmission housing.

-- Remove the left flange shaft bolt. To do this, install two bolts in the flange and counterhold it using a tire iron.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the flange shaft with the pressure spring.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lock the input shaft as follows:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The Stub Shaft Splines on the Input Shaft Have Different Lengths on the Transmission.

-- Either place the Press Piece - Multiple Use :VW455  over the input shaft on the clutch housing.

-- Or place the Press Piece - Front Wishbone :3160  over the input shaft on the clutch housing.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tension the Splitter :VAS251407  , -A-, or for example the Splitter :Kukko 17/0  behind the drive axle splines.

The back of the Separating Tool - 5-60mm must touch the Press Piece - Multiple Use :VW455  or the Press Piece - Front Wishbone :3160  free-of-play.