Disassembling and Assembling Transmission Housing
Disassembling and assembling transmission housing
Tools
Overview
Disassembling transmission housing
Preliminary work
1. Remove transmission.
2. Drain transmission oil.
3. Disassemble transmission.
Removing sliding latch
1. Unscrew Torx screws (no. 2 in overview) and remove sliding latch (no. 4 in overview).
Removing bleeder
1. Pull off cap (No. 6 in overview).
2. Force out bleeder (no. 5 in overview) using internal puller 7 - 10 mm, special tool threaded piece vw 771/15 and special tool striker vw 771.
Removing selector force mechanism
1. Remove circlip (no. 7 in overview).
2. Make a hole in the lid (no. 8 in overview) using a sharp object (e.g. a scriber).
3. Screw tapping screw into the lid.
4. Engage slide-hammer puller set in tapping screw and force out the lid.
5. Remove compression spring (No. 9 in overview).
Disassembling selector mechanism
1. Remove lock washer (no. 10 in overview).
2. Pull selector force lever (no. 11 in overview) off the selector lever (no. 12 in overview).
3. Pull selector lever out of the transmission housing.
4. Lever out sealing ring (no. 14 in overview) using a screwdriver.
5. Unscrew bearing screw (no. 15 in overview) using special tool socket-wrench insert 9658.
6. Remove swivel arm (no. 16 in overview).
7. Remove shift pinion (No. 17 in overview).
Removing ball sleeves
1. Force out ball sleeve (no. 18 in overview) using internal puller 14 - 20 mm, special tool threaded piece vw 771/15 and special tool striker vw 771.
Removing bearing for input shaft
1. Remove sealing ring (no. 19 in overview) from transmission housing using special tool hook vw 681.
2. Force out bearing for input shaft (no. 20 in overview) using internal puller 30 - 40 mm, special tool threaded piece vw 771/15 and special tool striker vw 771.
Assembling transmission housing
Installing bearing for input shaft
1. Drive new bearing for input shaft (no. 20 in overview) in as far as the mounting face using special tool pressure piece t10258.
2. Drive new shaft sealing ring (no. 19 in overview) in as far as the mounting face using special tool pressure piece 9628.
Installing ball sleeves
Information
^ Check installation depth of ball sleeves. The installation depth of the ball sleeves is measured from the sealing face and is 15 mm.
1. Tap in ball sleeves (no. 18 in overview) using special tool pressure piece 9648.
Assembling selector mechanism
1. Insert shift pinion (no. 17 in overview) into transmission housing.
2. Insert swivel arm (no. 16 in overview) and bearing screw (no. 15 in overview) into transmission housing and tighten bearing screw using special tool socket-wrench insert 9658.
Tightening torque: 50 Nm (37 ftlb.)
3. Tap new sealing ring (no. 14 in overview) in as far as the mounting face using special tool pressure piece 9694/7.
4. Fit selector lever (no. 12 in overview) and selector force lever (no. 11 in overview) at the correct positions. (The driver cross is vertical and the selector lever reaches the flat surface of the housing.)
5. Fit lock washer (no. 10 in overview) at the correct position and make sure it is seated correctly.
Installing selector force mechanism
1. Insert compression spring (no. 9 in overview) into transmission housing.
2. Insert lid (no. 8 in overview) and circlip (no. 7 in overview) into the bore on the housing.
3. Use special tool press-out mandrel p 375 to press the lid and circlip down until the circlip engages in its groove.
Installing bleeder
Information
^ Check installation depth of the bleeder, see illustration.
1. Tap bleeder (no. 5 in overview) into the transmission housing with a rubber hammer.
2. Fit cap (no. 6 in overview) on bleeder.
Installing sliding latch
1. Insert sliding latch (no. 4 in overview) into the transmission housing at the correct position and screw in Torx screws (no. 3 in overview).
Tightening torque: 20 Nm (15 ftlb.)
Subsequent work
1. Assemble transmission.
2. Fill with transmission oil.
3. Install transmission.
