Transmission Cover

Transmission Cover

Special tools, testers and auxiliary items required

• Thrust plate (VW 401)

• Thrust plate (VW 402)

• Punch (VW 408 A)

• Punch (VW 412)

• Slide Hammer-Complete Set (VW 771)

• Holding plate (VW 801)

• Thrust ring (2006 A)

• Lock pin (2064)

• Thrust pad (3062)

• Alignment fixture (3253)

• Internal extractor (Kukko 21/2)

• Internal extractor (Kukko 21/4)

• Support (Kukko 22/2)

• Depth gauge

• Stud M10

Press needle bearing out of transmission cover





- Remove peening indentations, if present.

Press needle bearing into transmission cover





Install needle bearings with lettering on bearing (the side with thicker metal) facing towards thrust pad (3062).

- Press in needle bearing to a depth of 262 ± 0.5 mm, measured from housing joint surface to needle bearing (similar to Ill. A34-10190 => [ Ball sleeve press-in depth in transmission
cover ] ).

- Secure needle bearing after pressing into transmission cover with peen, refer to => [ Secure needle bearing and roller housing in
transmission cover with peen ]

Remove ball sleeve from transmission housing





A Support, e.g. ( Kukko 22/2)
B Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)
C Stud M10

• You can also use adapter (VW 771/44) in place of stud M10 and (VW 771/15).

Press ball sleeve into transmission cover





- Set ball sleeve in place with inscribed side (thicker wall) facing toward lock pin (2064). To do this, insert smaller dia. of lock pin (2064) in ball sleeve.

- Support transmission cover under bearing mount with thrust ring (2006 A).

Ball sleeve press-in depth, refer to => [ Ball sleeve press-in depth in transmission cover ]

Ball sleeve press-in depth in transmission cover





- Press in ball sleeve for reverse gear selector rod - 1 - and 1st/2nd gear selector rod - 2 - to dimension - a - = 250.5 ± 0.5 mm.

Remove roller sleeve from transmission cover





A Support, e.g. ( Kukko 22/2)
B Internal puller 30 to 37 mm, e.g. (Kukko 21/4)

- Remove peening indentations, if present.

• Always replace roller sleeve after removing.

Carefully press new roller sleeve into transmission cover to stop.





Support transmission cover under bearing mount with thrust ring (2006 A).

- Secure roller sleeve after pressing into transmission cover with peen, refer to => [ Secure needle bearing and roller housing in
transmission cover with peen ]

Secure needle bearing and roller housing in transmission cover with peen





- To peen, use blunt center punch with ball-shaped end (ball dia. 5 mm).

- Needle bearings - 1 - or roller sleeves - 2 - are secured with three peen marks each on the circumference every 120 degrees - arrow A - or - arrow B -.

Observe position and dia. of peening points:

• Dimension - a - = 2 mm

• Dimension - b - = 3 mm