gearbox - disassemble and assemble — VW

🧭 Before you start

Mount the gearbox on its bracket, drain it, and remove the clutch lever, release bearing and the clutch housing. Remove the differential, gear selector VX65, speed sender G182 and clutch actuator VX64, then the thrust rings, reverse gear and bearing. On the rotating bracket, ease out the selector fork shaft and remove the input shaft, planet pinion and forks. Reassemble in reverse, seal the housing joint with AMV 188 200 and tighten the clutch housing to specification before refitting the actuators and sensor.

Fits: platform codes 6A1, 6A5

Don't miss

• Lever the clutch housing off evenly round its shoulders without damaging the sealing faces.
• Do not press the sliding sleeve outwards, or internal parts come out uncontrolled.
• Lift the input shaft slightly when removing the reverse gear.
• Apply sealing compound AMV 188 200 evenly to the housing sealing surface.
• Refit the oil drain plug before refilling.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Fasten the gearbox to the Bracket T10484.
2. Place the oil collector under the gearbox.
3. Remove clutch lever (A) with the clutch bearing and bearing guide (arrows).
4. Remove the fastening bolt from the clutch housing.
5. Remove the clutch housing carefully by leveraging via shoulders around the whole case alternately, without damaging the sealing surfaces.

6. Remove differential (A) from the gearbox housing.
7. Remove the Gear selectorVX65.
8. Remove the fastening bolt (arrow) of the Gearbox input speed sensor G182.
9. Remove the Gearbox input speed sensor G182.
10. Remove the Clutch actuatorVX64.
11. Remove the following in sequence: thrust ring (1), reverse gear (2), roller bearing (3) and thrust ring (4). [Note: When removing the reverse gear, lift the input shaft slightly and press it from the reverse gear.]
12. Place the gearbox housing as illustrated, through the Gearbox and engine rotating bracketVAS 6095.
13. Pull the selector fork shaft (1) slightly outwards. [Note: Do not press the sliding sleeve (arrow) outwards. Fitting parts are pressed out and removed without control.]
14. Slide the selector forks (A), (B) and (C) over the shaft.
15. Place the planet pinion (A), input shaft (B) with selector forks (C) .
16. Place the gearbox housing as illustrated, through the Gearbox and engine rotating bracketVAS 6095. [Note: Do not press the sliding sleeve (arrow) outwards. Fitting parts are pressed out and removed without control.]
17. Place the gearbox housing on the rotating bracket, in vertical position.
18. Press the input shaft, planet pinion, and selector fork shaft (1) on its seats.
19. Install the following sequence: thrust ring (1), reverse gear (2), bearing (3) and thrust ring (4).
20. Install differential (A).
21. Apply Sealing compoundAMV 188 200 evenly on the sealing surface of the gearbox housing.
22. Install the clutch housing on the gearbox housing and tighten screws to the specified tightening torque .
23. Install the clutch release lever .
24. Install the oil draining bolt (plug) (seta).
25. Install the Clutch actuatorVX64.
26. Install the Gear selectorVX65.
27. Install the Gearbox rotation sensor G182(arrow).

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