Disassembling and assembling front transmission Cover
345537 Disassembling and assembling front transmission CoverTools
Tools
Overview
Information
- The sintered metal bushings in the tramission cover cannot be replaced.
Disassembling front transmission cover
Preliminary work
1. Remove transmission.
2. Drain transmission oil.
3. Remove transmission cover.
Disassembling reverse idler gear
1. Unscrew the hexagon-head bolt (no. 5 in overview).
2. Remove bearing segment (no. 6 in overview) by pulling it forward.
3. Remove reverse idler gear (no. 7 in overview), needle-roller bearing (no. 8 in overview) and shaft (no. 9 in
overview).
Removing reversing-light switch
1. Unscrew reversing-light switch (no. 10 in overview) out of transmission cover.
Removing cylindrical-roller bearing with outer ring
1. Remove cylindrical-roller bearing (no. 11 in overview).
2. Force out outer bearing ring (no. 12 in overview) using special tools puller 9694/5 and pressure piece vw 771 .
Removing outer bearing ring
1. Force out outer bearing ring (no. 13 in overview) using internal puller 60 - 70 mm, No. 108" , special tool threaded piece vw 771/15 and special
tool striker vw 771 .
Disassembling gearshift mechanism
1. Take off roller (no. 14 in overview).
2. Remove lock washer (no. 15 in overview).
3. Pull shift segment (no. 16 in overview) off the gearshift lever.
4. Pull out gearshift lever (no. 17 in overview).
5. Lever out shaft seal (no. 18 in overview) with a screwdriver.
Removing ball sleeves
1. Force out ball sleeve (no. 20 in overview) using internal puller 14 -20 mm, No. 108" ,special tool threaded piece vw 771/15 and special tool striker vw 771 .
Assembling front transmission cover
Installing ball sleeve
Information
- Check installation depth of ball sleeves.
1. Drive new ball sleeve into the transmission cover using special tool pressure piece 9648 .
1 - The installation depth of the ball sleeve -1- is measured from the sealing face and is 257 mm.
2 - The installation depth of the ball sleeve -2- is measured from the sealing face and is 275.5 mm.
Assembling gearshift mechanism
1. Drive new shaft sealing ring (no. 18 in overview) in as far as the mounting face using special tool pressure piece 9694/7 .
2. Carefully insert gearshift lever (no. 17 in overview). The sealing lip on the shaft sealing ring must not be damaged.
3. Fit shift segment (no. 16 in overview) on the gearshift lever.
4. Fit lock washer (no. 15 in overview).
5. Fit the roller (no. 14 in overview) in place with grease.
Fitting outer bearing ring
1. Tap outer bearing ring (no. 13 in overview) in as far as the mounting face using special tool pressure pieces 9694/6 and pull-in tool and extractor p 254 .
Fitting cylindrical-roller bearing with outer ring
1. Tap outer bearing ring (no. 12 in overview) in as far as the mounting face using special tool pressure pieces 9694/6 and pull-in tool and extractor p 254 .
2. Lubricate cylindrical-roller bearing (no. 11 in overview) with transmission oil and insert it.
Fitting reversing-light switch
1. Screw reversing-light switch (no. 10 in overview) into the transmission cover.
Tightening torque: 18 Nm (13 ftlb.)
Fitting reverse idler gear
1. Insert shaft (no. 9 in overview) into the transmission cover. The threaded bore on the shaft must be aligned with the bore in the transmission cover.
2. Lubricate new needle-roller bearing (no. 8 in overview) with transmission oil and fit it on the shaft.
3. Fit reverse idler gear (no. 7 in overview) on the shaft.
4. Fit bearing segment (no. 6 in overview) on the shaft. The bore in the bearing segment must be aligned with the bore in the transmission cover.
5. Screw in hexagon-head bolt (no. 5 in overview).
Tightening torque: 25 Nm (19 ftlb.)
Subsequent work
1. Fit transmission cover. ? 343537 Disassembling and assembling transmission
2. Top up transmission oil.
3. Install transmission
Tightening torques
