Partially dismantling and assembling gearbox, removing and installing 5th and 6th gears — VW

🧭 Before you start

Fits: platform codes 5C7, 5C1

• Special tools named: puller, feeler gauge

Don't miss

• If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.
• The gear wheel for 6th gear with cylindrical roller bearing inner race can also be pulled off using two arm puller T10040 and puller hooks T10040/2A.
• One corrugated spring washer is fitted below 5th gear synchro-ring and one above 6th gear synchro-ring .Check both corrugated spring washers for damage.
• When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.Heat gear wheel slightly with hot air blowerV.A.G 1416 if necessary.
• Heat gear wheel for 5th gear to about 100 °C with inductive heaterVAS 6414 before installing.

📋 Procedure

1. Remove clutch release lever and release bearing .
2. Secure gearbox on gearbox supportVW 353.
3. Remove gearbox housing cover (arrow).
4. Remove cover, if necessary carefully levering up all around along protruding housing flange and alternating between sides, being careful not to damage sealing surfaces.
5. Check whether puller hooks T10040/2A can be inserted correctly under 5th gear wheel.

6. Remove selector fork for 5th and 6th gears as follows:
7. Cover openings in gearbox housing using a cloth.
8. Engage 5th gear (arrow 1) and (2).
9. Remove selector jaw for 5th/6th gear (bolt A).
10. Then remove both bolts (B) for pivot pins.
11. Pull out pivot pin.
12. Remove selector fork for 5th and 6th gears.
13. Unscrew (bolts A) for inner races on input and output shafts. To do so, engage 5th gear (arrow 1) and 1st gear (arrow 2) and (arrow 3).
14. Input shaft and output shaft are locked when both gears are engaged. Both bolts can now be loosened. [Note: If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.]
15. Pull off gear wheel for 6th gear with cylindrical roller bearing inner race for output shaft. [Note: The gear wheel for 6th gear with cylindrical roller bearing inner race can also be pulled off using two arm puller T10040 and puller hooks T10040/2A.]
16. Heat gear wheel slightly with hot air blowerV.A.G 1416 if necessary.
17. First, insert half sleeve T10309/1 between output shaft (A) and support for selector fork for 5th/6th gear (B).
18. Turn half sleeve T10309/1 to opposite side (direction of arrow).
19. Insert thread insert T10309/3 into half sleeve.
20. Now, insert second half sleeve T10309/1 and fit tube T10309/2 onto assembly.
21. After pulling off synchro-hub, examine for damage.
22. Renew 5th gear synchro-ring. [Note: One corrugated spring washer is fitted below 5th gear synchro-ring and one above 6th gear synchro-ring .Check both corrugated spring washers for damage.]
23. Now remove sleeve from gear wheel for 5th gear.
24. Pull off gear wheel for 5th gear.
25. First, insert puller hook (A). [Note: When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.Heat gear wheel slightly with hot air blowerV.A.G 1416 if necessary.]
26. Lock bolt of support bridge30 - 211 A with nut (A).
27. Heat gear wheel for 5th gear to about 100 °C with inductive heaterVAS 6414 before installing.
28. ⚠ Wear protective gloves! — Drive on gear wheel for 5th gear.
29. Before installing synchromeshed gears and synchro-rings for 5th and 6th gear, press synchro-rings onto cones of synchromeshed gears and measure gap (a) with a feeler gauge.
30. Install 5th gear synchromeshed gear with needle bearing.
31. Place corrugated spring on 5th gear wheel .
32. Then, place 5th gear synchro-ring on synchromeshed gear.
33. If synchro-hub and locking collar for 5th and 6th gear are dismantled, assemble before installing and .
34. Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.
35. Heat synchro-hub for 5th/6th gear to about 100 °C with inductive heaterVAS 6414 before installing.
36. ⚠ Wear protective gloves! — Drive on synchro-hub for 5th and 6th gear. [Note: When driving on, ensure that synchro-ring moves freely.]
37. Heat inner race of cylindrical roller bearing for 6th gear synchromeshed gear to maximum 100° C and drive onto input shaft.
38. ⚠ Wear protective gloves! — Install synchro-ring for 6th gear.
39. Place wave spring on 6th gear synchro-ring.
40. Install synchromeshed gear for 6th gear with needle bearing.
41. Cylindrical roller bearing inner race (B) and thrust washer (A) are combined in one component.
42. Heat cylindrical roller bearing inner race to maximum 100° C and drive onto input shaft.
43. ⚠ Wear protective gloves! — Place sleeve (A) on gear wheel for 5th gear.
44. Heat gear wheel for 6th gear to maximum 120° C.
45. ⚠ Wear protective gloves! — Shift locking collar for 5th and 6th gear to neutral position to enable synchromeshed gear for 6th gear to turn while gear wheel for 6th gear is being pressed on.
46. Drive on gear wheel for 6th gear, ensuring that teeth of gear wheel and synchromeshed gear for 6th gear mesh properly.
47. Heat cylindrical roller bearing inner race (A) to maximum 100° C and drive onto output shaft.
48. ⚠ Wear protective gloves! — Unfasten support for drive shaft.
49. If not already done, clean residual locking material out of threaded holes for securing bolts (A) using a thread chaser. Otherwise the bolts may shear.
50. Tighten new securing bolts for synchro-hub and gear wheels for 5th and 6th gears to specified torque.
51. Before tightening securing bolts (A), engage 2 gears (arrow 1) to (arrow 3).
52. Fit selector fork for 5th and 6th gears.
53. Engage 5th gear.
54. Loosen bolt (1).
55. Press down selector jaw and locking collar (arrows), and tighten bolt (1) to specified torque.
56. If necessary, repeat adjustment.
57. Engage 5th gear and then 6th gear.
58. Disengage gear.
59. Shift through all gears.
60. Apply sealantAMV 188 200 03 evenly to sealing surface of gearbox housing cover.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft · 47 torque figures
• Adjusting valve timing · 83 torque figures
• Removing and installing camshafts · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing oil seal for left flange shaft
• Draining and filling with coolant
• 5-speed gearbox 085 DS Lupo 3 L, Lupo FSI — Repairing clutch housing
• 5-speed gearbox 085 DS Lupo 3 L, Lupo FSI — Adjusting selector finger and selector sleeve
• Checking intake manifold flap motor V157