Servicing gearbox housing for vehicles with engines up to 103 kW — VW

Special tools and workshop equipment required

VW 447 H Press plate
VW 771 Multi-purpose tool
30-100 Drift sleeve
3002 Press tool
3301 Assembly tool
3 - Kukko 204/1 Puller
4 - Kukko 128/2 Ball joint splitter

Special tools and workshop equipment required

12-551 Centring mandrel

2004 Gearbox holder

Gearbox housing
If replaced: Adjust input shaft, output shaft and differential => Page
39-49
Modification: Holes in housing have been adapted to accommodate deletion of reverse gear locking unit -item
10
- and the simultaneous introduction of a 3rd stop sleeve -item
12
-.

Oil seal
Always renew

Oil filler plug, 25 Nm
Shim
For input shaft
Adjustment overview
=> Page
39-49

Outer race/taper roller bearing
For input shaft
Removing and installing
=> from Page
35-14
If replaced: Adjust input shaft
=> Page
35-16

Outer race/taper roller bearing
For output shaft
Removing and installing
=> from Page
35-50
If renewed: Adjust output shaft
=> Page
35-52

Shim S2
For output shaft
Adjustment overview
=> Page
39-49

Outer race/taper roller bearing
For differential
Removing and installing
=> from Page
39-9
If replaced: Adjust differential
=> Page
39-50

Shim
For differential
Adjustment overview
=> Page
39-49

Locking unit
For reverse gear
Removing => Fig.
1
Driving in => Fig.
2
Discontinued on gearboxes where the gear stick is not depressed to select reverse gear

Stop sleeves
With collar
Removing => Fig.
3
If renewed, install stop sleeve -item
12
- => Fig.
5

Stop sleeves
Without collar
Removing => Fig.
4
Driving in => Fig.
5
Three stop sleeves are installed in gearboxes where the gear stick is not depressed to select reverse gear

Oil seal
Renewing => Page
39-1

Fig.1
Removing locking unit for reverse gear

A -
Ball joint splitter (commercial type) e.g. Kukko No. 128/2
B -
Hexagon nut M10

Fig.2
Drive in reverse gear locking unit onto stop

Fig.3
Removing stop sleeve with collar

A -
Puller Kukko 204-1

Tension puller under collar (arrow).
Place a lever under puller and lever stop sleeve out.

Fig.4
Driving out stop sleeves without collar

Fig.5
Driving stop sleeve (without collar) in onto stop

Drive stop sleeve in onto stop with 13 mm socket -A- and plastic head hammer.