020 Transmission Disassembly

- Mount the transmission in assembly stand.
- Drain transmission oil.





- Remove clutch push rod (A) from input shaft.





- Fit input shaft support bridge 30-211A.
^ (A) Lock nut - M12.
- Press VW 295a to stop on input shaft using bolt and lock with lock nut (A).





- Loosen bolts for transmission housing cover (arrow) and remove the entire assembly.





- Remove the lock bolt (arrow) for selector shaft (A).
- Remove the vehicle speed sensor (B).





- Use spark plug wrench (A) (part no. 311 012205 A or equivalent) to loosen the selector shaft cover and remove the cover together with the spring.
- Bring the shift forks into neutral position and extract the selector shaft.





- Remove the Torx(r) bolt (arrow) for reverse idler gear shaft.





- Remove the left-side drive flange.





- Engage 5th gear (arrow 1).
- Engage reverse gear (arrow 2), (front shift fork slot moved downward).





- Remove the synchronizer hub retaining bolt using a 12 mm 12-point socket-head wrench.





- Press off the selector tube securing plate.





- Turn the selector tube counter-clockwise to remove it from the shift fork.

CAUTION: DO NOT pull the selector rod from the selector tube.





- Remove the synchronizer hub together with 5th gear and shift fork, using two levers to pry free if necessary.

CAUTION:
- Take care to avoid damaging the housing sealing surfaces.
- Note the gear thrust washer below the synchronizer hub.





- Remove the circlip and thrust washer for 5th gear.

NOTE: On vehicles with 2.0 liter, 85 kW (115 hp) engine, the 5th gear circlip is replaced by securing plate (A).





- Remove 5th gear using a two-legged puller if necessary.
^ (A) Kukko 20/10 with Matra V 170 hook (or equivalent).





- Remove the tension bracket for the deep groove ball bearing for the input shaft.
- Remove the socket-head bolts retaining the transmission housing (arrows).





- Pull off the transmission housing.





- Pull the selector rod (A) from the bore in the clutch housing and remove shift fork (B).





- Remove the circlip for 4th gear from the output shaft.
- Remove 4th gear, using a 2-legged puller if necessary. (A) Kukko 20/10 with Matra V 170 hook (or equivalent).





- Remove complete input shaft (A).

NOTE: Reverse gear (B) must not be engaged.





- Remove circlip (A).

NOTE: Only vehicles with 2.0 liter 85kW (115 hp) engine are equipped with an additional circlip (A) for 4th gear.

- Remove circlip (B).





Press off 3rd gear with 2nd gear.
^ (A) Two-arm puller, e.g. Kukko 20/10 with 250 mm hooks.
- Remove the synchronizer ring and needle bearing.
- Drive out the reverse gear shaft with bolt (threaded in, arrow) using a plastic hammer.
- Remove reverse gear from the relay lever.





- Pull off the synchronizer hub/operating sleeve and 1st gear together with the inner race for the needle bearing of 2nd gear.
^ (A) Kukko 20/10 (or equivalent) with 250 mm hook.





- Remove bearing cover bolts (arrows) and cover. Note thrust washer (1).
- Remove the output shaft.





- Remove the right-side drive flange.
- Remove the differential.

CAUTION: Watch for tapered ring (A) and thrust washer (B) for drive flange spring.