Transmission Housing and Clutch Housing

Overview - Transmission Housing

1. 1
   Transmission Housing

   • When replacing: adjust the output shafts and differential.
   • Changes near the mount area for the cover/input shaft.
   • Allocate component according to the Parts Catalog
2. 2
   Cap

   • Removing.
   • Installing.
3. 3
   Oil Drain Plug

   • Tightening specification.
4. 4
   Seal

   • if present, replace after removing
5. 5
   Oil Filler Plug

   • Tightening specification.
6. 6
   Locking Elbow

   • Adjusting the gearshift mechanism.
   • Can be replaced with transmission not disassembled
   • Removing
   • Installation position.
   • Installing.
7. 7
   Bearing Bushing

   • For the selector rods
   • Removing.
   • Installing.
8. 8
   Retaining Sleeve

   • Removing when the transmission is disassembled.
   • Removing when the transmission is not disassembled.
   • Different retaining sleeves.
   • Installing a retaining sleeve with a shoulder.
   • Installing the retaining sleeve without a shoulder.
9. 9
   Needle Sleeve

   • For the reverse shaft
   • Replace after removing
   • Removing.
   • Installing.
10. 10
    Outer Race/Tapered Roller Bearing

    • Output Shaft, 5th, 6th and Reverse Gears
    • Removing and installing.
    • When replacing: adjust output shaft for 5th/6th and reverse gear.
11. 11
    Shim

    • Output Shaft, 5th/6th and Reverse Gears
    • Adjustment overview.
12. 12
    Outer Race/Tapered Roller Bearing

    • Output Shaft, 1st to 4th Gears
    • Removing and installing.
    • Adjust, if output shaft for 1st to 4th gear is replaced.
13. 13
    Shim

    • Output Shaft, 1st to 4th Gears
    • Adjustment overview.
14. 14
    Outer Race/Tapered Roller Bearing

    • For the differential
    • Removing and installing.
    • When replacing: adjust the differential.
15. 15
    Shim

    • For the differential
    • Adjustment overview.
16. 16
    Bearing Bushing

    • For the selector shaft
    • Removing.
    • Installing.
17. 17
    Plugs

    • Removing.
    • Installing.
18. 18
    Seal

    • For the left flange shaft
    • Replace after removing.

Overview - Clutch Housing

1. 1
   Bearing Bushing

   • For the selector rods
   • Replace after removing
   • Removing.
   • Installing.
2. 2
   Needle Sleeve

   • For the reverse shaft
   • Replace after removing
   • Removing.
   • Installing.
3. 3
   Alignment Sleeve

   • Quantity: 2
4. 4
   Clutch Housing

   • When replacing: adjust the output shafts and differential.
5. 5
   Cap

   • Not on all clutch housings
6. 6
   Input Shaft Seal

   • Replace after removing.
7. 7
   Seal

   • Replace after removing
   • FWD - for the right flange shaft
   • FWD.
   • FWD with front axle differential lock between the manual transmission and the front axle differential lock.
   • AWD - between the manual transmission and bevel box
   • AWD.
8. 8
   Washer

   • Installed position: the shoulder on the inner diameter faces the seal -item 7-
   • Outer Race/Tapered Roller Bearing
9. 9
   For the differential

   • FWD, removing and installing.
   • FWD with Front Axle Differential Lock, Removing and installing.
   • AWD, removing and installing.
   • When replacing: adjust the differential.
10. 10
    Oil Deflector Ring

    • Installed position: shoulder at hole points toward output shaft
11. 11
    Outer Race/Tapered Roller Bearing

    • Output Shaft, 1st to 4th Gears
    • Removing and installing.
    • Adjust, if output shaft for 1st to 4th gear is replaced.
12. 12
    Outer Race/Tapered Roller Bearing

    • Output Shaft, 5th, 6th and Reverse Gears
    • Removing and installing.
    • When replacing: adjust output shaft for 5th/6th and reverse gears.
13. 13
    Washer

    • Output Shaft, 5th/6th and Reverse Gears
    • Always 0.65 mm thick
14. 14
    Cylindrical Roller Bearing

    • For the input shaft
    • Removing and installing.
15. 15
    Magnet

    • Held in place by housing joint surface

Transmission Housing, Servicing

Special tools and workshop equipment required

• Bearing Driver - Multiple Use -VW244B-
• Transmission Support -VW353-
• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW407-
• Press Piece - 37mm -VW416B-
• Guide Pin -VW436A-
• Press Piece - Guide Pin -VW439-
• Slide Hammer Set -VW771-
• Crankshaft Holding Fixture -VW801-
• Guide Pins -10-15-
• Press Piece - Pivot Mount Bushing -3124-
• Bearing Installer - Crankshaft Pilot Bearing -3264-
• Subframe Support Tool -3290-
• Torque Wrench 1331 5-50Nm -VAG1331-
• Bushing Driver - Selector Shaft -T10168-
• Locking Sleeve Drift -T10169- or Locking Sleeve Drift -T10362-.
• Breather Tube Tool -T10203-
• -1-Puller - Kukko Internal - 14-19mm -21/2-
• -1-Puller - Kukko Internal - 20-30mm -21/4-
• -4-Puller - Kukko Counterstay -22/2-
• Thread adaptor from Puller - Kukko Counterstay -22/1-

Removing the Cover -A-

• Pierce the rubber in the center of the cover with a screwdriver -B- and pry it out of the cover in direction of -arrow-.

Installing the Cover

Removing the Locking Elbow for the Gearshift Shaft

• Break off the bracket in its unlocked position.
• Insert a screwdriver -A- into the hole in the locking bracket -B-.
• Pry out the locking elbow in direction of -arrow-.

Installed Position: Locking Elbow

• The mark on the locking elbow -arrow- must point toward the connection on the clutch slave cylinder -1-.
• Dimension -a- must be approximately 45º.

Drive Lock Elbow -arrow- for Selector Shaft in up to Tool Stop.

Note

The locking elbow must be unlocked when being installed.

Removing the Shift Rod Bearing Bushing

1. 1
   14.5 to 18.5 mm Internal Puller -21/2-, for example.
2. 2
   Puller - Kukko Counterstay -Kukko 22/2-, for example.

   

Installing the Shift Rod Bearing Bushing All the Way onto the Tool

Removing the Retaining Sleeve -A- from the Transmission Housing

• Place transmission housing on Press Plate -VW401- and press plate -VW402- in such a way so that the alignment sleeves inside the transmission housing do not get damaged.

Removing the Retaining Sleeve on a Transmission Not Disassembled Using the Guide Pins -10-15-.

• Locking bolt and selector shaft removed.
• Turn the transmission so that the retaining sleeve cannot fall into the transmission.

Lock Sleeve Differentiation

The following lock sleeves may be installed:

Lock sleeve with a shoulder -arrow 1-.

Lock sleeve without a shoulder -arrow 2-.

Allocate the components. Refer to the Parts Catalog.

Drive in Lock Sleeve with Shoulder as Far as Stop on Tool

• The transmission housing is bolted to the clutch housing.

Drive in Lock Sleeve without Shoulder as Far as Stop on Tool

• The transmission housing is bolted to the clutch housing.

Removing the Reverse Shaft Needle Sleeve from the Transmission Housing

1. 1
   Puller - Kukko Internal - 20-30mm -21/4-, for example.
2. 2
   Puller - Kukko Counterstay -22/2-, example.

   

Note

The needle sleeve will get damaged when it is removed and must be replaced.

Installing the Needle Sleeve -A- into the Transmission Housing

• Lay the reverse shaft thrust washer -B- on the needle sleeve while pressing it in.
• Support the transmission housing with the Press Piece - 37mm -VW416B- directly under the bearing mount.

Removing the Selector Shaft Bearing Bushing

• Use the thread adapter from Puller - Kukko Counterstay -22/1--arrow-.
• Hold the spindle on the Subframe Support Tool -3290- steady and turn the nut -B-.

1. Puller - Kukko Internal - 14-19mm -21/2-, for example.

Installing the Gearshift Shaft Bearing Bushing -A- All the Way Onto the Tool

Removing the Plug -1-

• Remove the plug -1- from the inside of the transmission housing to the outside.

Installing the Plug -1-

• Using the Bearing Installer - Crankshaft Pilot Bearing -3264-, drive in the sealing plugs to dimension -a- approximately 3 mm below the upper edge of the housing.

Clutch Housing, Servicing

Special tools and workshop equipment required

• Press Piece - Rod -VW407-
• Bushing Driver - Selector Shaft -T10168-
• Seal Installer - Drive Axle -T40008-
• -1-Puller - Kukko Internal - 14-19mm -21/2-
• -1-Puller - Kukko Internal - 20-30mm -21/4-
• -4-Puller - Kukko Counterstay -22/1-
• -4-Puller - Kukko Counterstay -22/2-

Removing the Shift Rod Bearing Bushing

1. 1
   Puller - Kukko Counterstay -22/1-, for example.
2. 2
   Puller - Kukko Internal - 14-19mm, for example.

   

Installing the Shift Rod Bearing Bushing All the Way onto the Tool

Removing the Needle Sleeve from the Clutch Housing

1. 1
   Puller - Kukko Counterstay -22/2-, for example.
2. 2
   Puller - Kukko Internal - 20-30mm -21/4-, for example.

   

Note

The needle sleeve will get damaged when it is removed and must be replaced.

Installing the Needle Sleeve -A- into the Clutch Housing

• Lay the reverse shaft thrust washer -B- on the needle sleeve while pressing it in.