6-speed manual gearbox 01E, four-wheel drive — Repairing gearbox housing — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

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• Installation in right gearbox side is illustrated in figure.The procedure is the same for both left and right sides.If previously used flange shaft is installed, repair pressing depth is 6.5 mm.
• Do not damage oil seal running surface on input shaft.
• If the used output shaft is reused, repair pressing depth is 4.5 mm.
• With gearbox removed but not dismantled, carefully lever out seal with a screwdriver without damaging shaft.
• To avoid damaging oil seal (C), always use assembly sleeve (A) part No. 01E 311 120 to install oil seal or selector shaft.

📋 Procedure

1. Half-fill space between sealing lip and dust lip with greaseG 052 128 A1. [Note: Installation in right gearbox side is illustrated in figure.The procedure is the same for both left and right sides.If previously used flange shaft is installed, repair pressing depth is 6.5 mm.]
2. Lever oil seal out carefully with a screwdriver. [Note: Do not damage oil seal running surface on input shaft.]
3. Half-fill space between sealing lip and dust lip of new seal with greaseG 052 128 A1.
4. Fit a thin protective hose tightly over splines of input shaft.
5. Press in input shaft oil seal. [Note: If the used output shaft is reused, repair pressing depth is 4.5 mm.]

6. Remove protective hose.
7. Remove retaining ring.
8. Install ball sleeve with inscribed side (thicker metal) facing drift.
9. Drive in to stop.
10. Fit retaining ring. [Note: With gearbox removed but not dismantled, carefully lever out seal with a screwdriver without damaging shaft.]
11. Half-fill space between sealing lip and dust lip with greaseG 052 128 A1.
12. Pull assembly sleeve onto selector shaft .
13. Drive seal into housing to stop.
14. To avoid damaging oil seal (C), always use assembly sleeve (A) part No. 01E 311 120 to install oil seal or selector shaft.
15. Tighten reversing light switch (A) to specified torque when installing. [Note: Switch allocation Electronic parts catalogue
16. Lift one end of retaining ring out of groove by turning screwdriver (A).
17. Secure this end with a screwdriver (B).
18. Lever retaining ring out further by repositioning screwdriver (A).

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