Assembly order, gearbox »without« circlip A for input shaft cover made from sheet metal — VW

Assembly order, gearbox
»without«
circlip
A
for input shaft cover made from sheet metal
Removing and installing gearbox housing, selector mechanism, input shaft, output shafts, differential, selector rods and, if applicable, bevel box
Special tools and workshop equipment required
Support plate
VW 309
Support clamp
VW 313
Gearbox support
VW 353
Installing sleeve
VW 455
or
Sleeve
3160
Multipurpose tool
VW 771
Sleeve
30 - 21
(is not required)
Support bridge
30 - 211A
Thrust piece
T10042
Drift
T10169
Thrust piece
T40008
Torque wrench
V.A.G 1331
Hot air blower
V.A.G 1416
Drift
T10362
1
Internal puller
Kukko 21/01
3
Splitter
Kukko 17/0
4
Counter support
Kukko 22/1
Dismantling
Mount gearbox on
support clamp
VW 313
with
gearbox support
VW 353
and
retaining plate
VW 309
.
Secure gearbox to
gearbox support
VW 353
with suitable bolts
arrow
.
Note
If one of the bolting holes does not contact the
gearbox support
, lay a washer between the hole and the
gearbox support
.
Rotate gearbox on assembly stand so that oil drain plug is below.
Set drip tray under gearbox.
Drain gear oil.
Gearbox for all-wheel drive
Remove right flange shaft countersunk bolt with
socket
.
Remove the 4 connecting bolts
arrows
for bevel box to gearbox (only 3 are visible in figure).
Carefully press bevel box off gearbox, taking care that it does not fall.
Gearbox for front-wheel drive
Remove right flange shaft (fig. shows left flange shaft).
Continuation for all
Remove clutch slave cylinder with clutch release bearing
arrows
.
Unscrew all bolts
B
from clutch housing and remove them.
Note
One bolt
arrow
is located outside of bolting flange.
The lengths of the splines on the input shaft to the gearbox differ.
Set either
installing sleeve
VW 455
over input shaft on clutch housing
or set
sleeve
3160
over input shaft on clutch housing
Clamp
splitter
A
, e.g.
Kukko 17/0
, behind input shaft splines.
The back side of the
splitter
must rest against
installing sleeve
VW 455
or
sleeve
3160
without play.
Remove left flange shaft.
During the following steps, ensure that the selector shaft is not blocked by the angled rod
arrow
.
Move selector shaft to neutral.
Remove locking bolt
2
.
Then remove bolts
3
.
Remove
reversing light switch
F4
1
.
Pull selector shaft
4
out of gearbox housing.
Note
To prevent selector shaft
1
from hitting locating sleeve
2
during removal, press against force of spring using
removal lever
80 - 200
in
direction of arrow
.
Pierce rubber in centre of cover
C
with a
screwdriver
.
Pull sealing cover out of gearbox housing.
A
Counter support
, e.g.
Kukko 22/1
B
Internal puller, 8…12 mm
, e.g.
Kukko 21/01
Note
Cover plate
1
can also be levered off carefully using a screwdriver
2
.
Remove retaining ring
C
from deep groove ball bearing of input shaft in gearbox housing as follows:
Hold one end of retaining ring using
screwdriver
A
.
Using a
screwdriver
B
, lever other end out of groove in deep groove ball bearing in
direction of arrow
.
Using
screwdriver
B
, you can lever out retaining ring further.
If present, remove washer
1
from gearbox housing
2
.
If gearbox housing is to be renewed, check whether washer must be installed
Anchor
.
Remove all securing bolts
A
for gearbox housing.
Heat gearbox housing using
hot air blower
, e.g.
V.A.G 1416
in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100° C.
Screw
adapter VW 771/40
into threaded hole of gearbox housing.
Using
multi-purpose tool VW 771/1
, carefully pull gearbox housing off clutch housing in direction of
arrow
.
Note
If necessary, remove gearbox housing by carefully levering at overhanging housing shoulders along perimeter alternately using assembly lever. Make sure not to damage the sealing surfaces while doing so.
If present, remove washer
1
from deep groove ball bearing
2
.
If gearbox housing is to be renewed, check whether washer must be re-installed
Anchor
.
Remove
splitter
A
and
installing sleeve VW 455
or
sleeve
3160
from input shaft.
To remove shafts from clutch housing, a second mechanic is required.
With one hand, raise differential
1
. With other hand, lift output shaft for 1st to 4th gears together with selector rods
2
arrow A
.
At the same time, have a 2nd mechanic lift the input shaft, reverse shaft and output shaft for 5th and 6th gears
3
together with selector rod out of clutch housing
arrow B
.
Note
After shafts are lifted, differential may be set back in clutch housing if desired.
Always renew deep groove ball bearing on input shaft
Item
.
Remove input shaft oil seal.
Assembling
A new deep groove ball bearing has been pressed onto the input shaft
Item
.
First insert input shaft
1
and 5th and 6th gear output shaft
2
together with selector rod
3
, selector fork
4
and reverse shaft
5
.
Insert differential
1
.
Note
A second mechanic will be required for further installation of shafts in clutch housing.
Take output shaft for 1st through 4th gears
3
with selector rods
4
in your hand as shown in figure.
With other hand, lift differential slightly.
At the same time, a 2nd mechanic must slightly lift input shaft and output shaft for 5th and 6th gears and reverse gear
2
together with reverse gear shaft.
Now insert output shaft for 1st through 4th gears
3
in
direction of arrow
.
Note
Make sure that teeth of input shaft, the output shafts and the differential input gear of differential are in mesh.
Together with second mechanic, place shafts and differential into bearing seats.
Secure
support bridge
30 - 211 A
for input shaft to clutch housing.
Note
For clarity of illustration, clutch housing is shown turned 180°.
Screw in bolt
A
until input shaft rises slightly.
On some gearboxes, flats
A
are present on the deep groove ball bearing for the input shaft and the bearing support
B
.
Check deep groove ball bearing for input shaft and gearbox housing.
Deep groove ball bearing for input shaft and gearbox housing
No flats on deep groove ball bearing
A
or on bearing support
B
Anchor
Flats on deep groove ball bearing
A
and on bearing support
B
Fig.
Gearboxes manufactured up to around 01.08:
A washer is installed above and one below the deep groove ball bearing for the input shaft
Item
.
Upper washer
Outer diameter
78.6 mm
Lower washer
Outer diameter
85 mm
Lay washer (outer diameter = 85 mm)
1
on deep groove ball bearing
2
.
Thoroughly clean sealing surfaces of gearbox and clutch housings.
Heat gearbox housing using
hot air blower
, e.g.
V.A.G 1416
in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100° C.
Note
Heating is necessary to avoid damage to deep groove ball bearing when gearbox housing is installed.
Apply
sealing paste
as per
Electronic Parts Catalogue
evenly to sealing surface of clutch housing.
Gearbox with flats on deep groove ball bearing for input shaft
A
and on bearing support
B
:
No washers may be laid above or below the deep groove ball bearing.
Flats
A
on deep groove ball bearing and on bearing support
B
in gearbox housing must line up.
Mark flats with coloured marks.
Transfer markings to upper area of deep groove ball bearing and to upper area of bearing support of gearbox housing (⇒ next figure).
Thoroughly clean sealing surfaces of gearbox and clutch housings.
Heat gearbox housing using
hot air blower
, e.g.
V.A.G 1416
in vicinity of bearing seat for deep groove ball bearing for input shaft for about 10 minutes to about 100° C.
Note
Heating is necessary to avoid damage to deep groove ball bearing when gearbox housing is installed.
Apply
sealing paste
as per
Electronic Parts Catalogue
evenly to sealing surface of clutch housing.
Note
Line up marking on deep groove ball bearing
A
with marking on gearbox housing
B
and set gearbox housing in place.
Continuation for all
Install gearbox housing using new bolts
A
,
B
and
C
.
For steel bolts (external hexagon socket head bolts) as replacement part, note allocation:
A
Bolt with captive washer.
B
Bolt without washer.
C
Bolt with captive washer.
If a washer was laid on the deep groove ball bearing before the gearbox housing was set in place, a washer
1
(outer diameter = 78.6 mm) must also be placed above the deep groove ball bearing
2
Anchor
.
Install retaining ring
1
for deep groove ball bearing of input shaft.
Remove
support bridge
30 - 211 A
for input shaft.
If stop sleeve for selector shaft has been removed, now drive it in to stop of tool
Chapter
.
Turn gearbox in repair stand with opening for selector shaft upwards.
Note
To prevent selector shaft
1
from hitting locating sleeve
2
during installation, press against force of spring using
removal lever
80 - 200
in
direction of arrow
.
Insert selector shaft
1
in lower bearing
2
and in selector forks
3
.
Note
For better clarity, sealing cover
Item
is removed in illustration.
Now press selector shaft
1
against stop sleeve
2
in
direction of arrow
and guide downwards with selector finger
3
through selector forks to stop.
Selector shaft cover
4
must be parallel to bolting surface on gearbox housing.
Selector shaft must move freely in gate selection direction (upwards and downwards).
Note
If selector shaft cover is tilted relative to bolting surface, selector shaft is not inserted in lower bearing.
Tighten bolts
3
for selector shaft cover
4
.
Screw in locking bolt
2
, ensuring that angled rod
arrow
is not engaged.
Install
reversing light switch
F4
1
.
Drive in input shaft oil seal flush.
Install clutch slave cylinder with release bearing
Chapter
.
Shift through all gears.
Drive in sealing cover for gearbox housing with
thrust piece
T10042
.
Install flange shafts together with springs, thrust washers and tapered rings.
Gearbox for all-wheel drive
Attach bevel box to gearbox as follows:
Grease splines of differential with
grease for clutch plate splines
G 000 100
.
Push bevel box completely onto gearbox, ensuring that splines of bevel box input shaft and differential are centred when brought together.
Align splines of right flange shaft and differential bevel gear, turning flange shaft if necessary.
If splines are correctly positioned and shafts are centred, then bevel box will slide to stop against gearbox.
Note
Do not use securing bolts to pull bevel box onto gearbox, or bevel box will cant and bolt holes can break off.
Tighten the 4 connecting bolts
arrows
for bevel box to gearbox (only 3 are visible in figure).
Tighten right flange shaft countersunk bolt with
socket
.
Continuation for all:
Fill gearbox with gear oil after installation.
Specified torques
Chapter
“
Assembly overview - clutch release mechanism
”
Chapter
“
Assembly overview - gearbox housing and selector mechanism
”
Chapter
“
Assembly overview – input shaft, output shafts, differential and selector rods
”
Chapter
“
Assembly overview - selector unit
”