Removing cover for gearbox housing and 5th and 6th gears — VW

🧭 Before you start

Fits: VW Golf Cabriolet (517, 2011–2016), VW Golf VII Variant (BA), VW CC (358, 2012–2017), VW Golf VII (5G, 2012–2020)

• Special tools named: puller
• Renewed: synchro-ring

Don't miss

• If the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.
• 6th gear wheel with cylindrical roller bearing inner race can also be pulled off using two arm puller T10040 and puller hooks T10040/2A.
• If necessary, half sleeve must be pressed to end position.
• 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.

📋 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 lever it off at protruding shoulders along perimeter alternately. Be careful not to damage sealing surfaces when doing this.
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 with 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 pins.
12. Remove selector fork for 5th/6th gear.
13. Unscrew (bolts A) for bearing 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 the shafts are to be reused, clean residual locking material out of threaded holes using a thread chaser.]
15. Pull off gear wheel for 6th gear together with inner race of cylindrical roller bearing for output shaft. [Note: 6th gear wheel with cylindrical roller bearing inner race can also be pulled off using two arm puller T10040 and puller hooks T10040/2A.]
16. If necessary, heat gear wheel slightly using hot air blowerV.A.G 1416, for example.
17. First, insert half sleeve T10309/1 between output shaft (A) and support for selector fork for 5th/6th gear (B).
18. If necessary, half sleeve must be pressed to end position.
19. Turn half sleeve T10309/1 to opposite side (direction of arrow).
20. Insert threaded insert T10309/3 into half sleeve.
21. Install second half sleeve T10309/1 now and fit tube T10309/2 onto assembly.
22. After pulling off synchro-hub, examine for damage.
23. Renew synchro-ring if necessary. [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.]
24. Now remove sleeve from gear wheel for 5th gear.
25. Pull off gear wheel for 5th gear.
26. 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.]

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