Repairing gearbox cover — VW

VW
Passat
1997
Passat Variant
1997
Power transmission
6-speed manual gearbox 0A2
Edition
09.2005
Repairing gearbox cover
Special tools and workshop equipment required
Thrust plate
VW 401
Thrust plate
VW 402
Press tool
VW 408 A
Multi-purpose tool
VW 771
Adapter
VW 771/44
Support plate
VW 801
Thrust piece
32 - 111
Thrust plate
40 - 105
Locking pin
2064
Assembly tool
3253
1
Internal puller
Kukko 21/2
1
Internal puller
Kukko 21/4
4
Counterhold
Kukko 22/2
Depth gauge
Gearbox cover
Dowel pin
Qty. 2
Insert in gearbox cover
Drive in until flush with back side of housing joint surface
Ball sleeve
For selector rod for reverse gear
Pulling out
Fig.
Pressing in
Fig.
.
Measuring pressing depth
Fig.
.
Ball sleeve
For selector rod for 1st and 2nd gears
Pulling out
Fig.
Pressing in
Fig.
.
Measuring pressing depth
Fig.
.
Roller sleeve
Bears input shaft in gearbox cover
Always renew
Pulling out
Fig.
Pressing in
Fig.
.
After installing, secure by peening
Fig.
Pulling ball sleeve out of gearbox cover
A
Counter support
, e.g.
Kukko 22/2
B
Internal puller, 14.5...18.5 mm
, e.g.
Kukko 21/2
Note
An M10 stud with
adapter
VW 771/15
can be used in place of
adapter
VW 771/44
.
Pressing ball sleeve into gearbox cover
Install ball sleeve with inscribed side (thicker metal) facing
mandrel
2064
. In the process, insert smaller ∅ of
mandrel
2064
in ball sleeve.
Support gearbox cover beneath bearing mounting with
thrust plate
40 - 105
.
Pressing depth of ball sleeve
Fig.
.
Pressing depth of ball sleeve in gearbox cover
Press in ball sleeve for reverse gear selector rod
1
and for selector rod for 1st and 2nd gears
2
to dimension
a
= 250.5 ± 0.5 mm.
Pulling roller sleeve out of gearbox cover
A
Counter support
, e.g.
Kukko 22/2
B
Internal puller, 30...37 mm
, e.g.
Kukko 21/4
If present, remove peening depressions.
Note
Always renew roller sleeve after it is pulled out.
Carefully press new roller sleeve into gearbox cover to stop.
Support gearbox cover beneath bearing mounting with
thrust piece
32 - 111
.
After roller sleeve is pressed in, secure in gearbox cover by peening
Fig.
.
Securing roller sleeve in gearbox cover by peening
Use a blunt punch with a ball-shaped end (5 mm ball ∅) to peen in position.
Secure roller sleeve
1
with 3 peening points along circumference offset by 120°
arrows
.
Observe position and diameter of peening points:
Dimension
a
= 2 mm
Dimension
b
= 3 mm