Shift Unit, Input Shaft, Output Shafts, Gearshift Rod, Differential And Bevel Box: Notes

Special tools and workshop equipment required

Holding Plate VW 309
Transmission Support VW 353
Thrust Tube VW 455
Slide Hammer-Complete Set VW 771
Adapter VW 771/44
Support Bridge T10323
Socket And Extended Bit T10107 A
Counter-Hold Tool 3435
Thrust Piece T10042
Counter Hold Tool T10371
Thrust Piece T10233
Hot Air Blower V.A.G 1416
Internal Puller 14.5 to 18.5 mm, for example Kukko 21/02
Separating Tool 5 to 60 mm, for example, Kukko 17/0
Counter-Support Kukko 22/1
Front and Rear Bearing Tool 3348/2
Sealing paste AMV 188 200 03
Grease G 060 735 A2

Removing

Fig 1: Attaching Transmission To VW 353 With Bolts

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-- Attach the transmission to the VW 353 with the bolts -arrows-.

-- Remove the right stub shaft bolt with the T10107 A; when doing this, counter-hold the stub shaft.

Fig 2: Removing Right Stub Shaft Bolt With T10107 A

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-- Remove the 4 bevel box connecting bolts -arrows- (only 3 shown in illustration) on the manual transmission.

-- Carefully push the bevel box off the manual transmission and remove it.

-- Remove the bolts -arrows-.

Fig 3: Identifying Slave Cylinder Bolts

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-- Remove the clutch slave cylinder with release bearing -A-.

-- Place a drip tray under the transmission.

-- Drain the transmission fluid.

-- Remove the clutch housing bolts to the transmission housing.

-- Mount the VW 455 over the input shaft on the clutch housing and secure the input shaft -B-.

Fig 4: Mounting VW 455 Over Input Shaft On Clutch Housing And Secure Input Shaft

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-- Tension the separating tool 5 to 60 mm -A-, for example Kukko 17/0, tightly behind the input shaft splines.

The back of the separating tool must touch the thrust tube free-of-play.

-- Move the shift unit selector shaft into the neutral position.

Fig 5: Moving Shift Unit Selector Shaft Into Neutral Position

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-- Remove the back-up lamp switch -F4- -A-.

-- Remove the bolts from the shift unit -B- on the transmission housing.

-- Remove the shift unit from the transmission housing; while doing this, rotate the shift unit 180° when removing it.

The shift unit shift fingers must be guided through the selector rods.

-- Remove the locking plate -1- (if equipped).

Fig 6: Removing Locking Plate

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-- Remove the bracket -2- (if equipped).

Fig 7: Removing Bracket

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-- Push the rubber through the center of the cover -C- using a screwdriver.

Fig 8: Pushing Rubber Through Center Of Cover Using A Screwdriver

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-- Pry the sealing cap out of the transmission housing.

-- If necessary, pull the cap off the transmission housing.

A - Counter-support, for example, Kukko 22/1

B - Internal puller 14.5 to 18.5 mm, for example, Kukko 21/02

Remove the locking ring -C- from the input shaft grooved ball bearing as follows:

Fig 9: Removing Locking Ring From Input Shaft Grooved Ball Bearing

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-- Hold one end of the locking ring with the screwdriver -A-.

-- Pry the other end of the locking ring out of the groove in the grooved ball bearing -arrow- with the second screwdriver -B-.

-- Reposition the screwdriver -B- and pry the locking ring out further.

-- Counter hold the stub shaft using the T10371 and remove the bolt from the left stub shaft -A-.

Fig 10: Counter Hold Stub Shaft Using T10371 And Remove Bolt From Left Stub Shaft

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-- Remove the stub shaft.

-- Remove all the bolts for the transmission housing to clutch housing.

NOTE:

If bolts -B- are present, then these do not need to be removed in order to remove the transmission housing.

-- Install the VW 771/44 all the way into the threaded bore in the transmission housing and secure it with the nut -A-.

Fig 11: Installing VW 771/44 Into Threaded Bore In Transmission Housing And Secure It With Nut

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-- Heat transmission housing using, for example, the V.A.G 1416, in the area of the bearing seat for grooved ball bearing/input shaft to approximately 100 °C (212 °F) for approximately 10 minutes.

-- Separate the transmission housing from the clutch housing using the VW 771. At the same time separate the transmission housing on the housing brace -arrow- from the clutch housing with a lever -B-.

-- Remove the separating tool -A- and the VW 455 from the input shaft -B-.

Fig 12: Removing Separating Tool And VW 455 From Input Shaft

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-- Remove the switching rockers for reverse gear -A-.

Fig 13: Removing Switching Rockers For Reverse Gear

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-- Carefully bring the transmission into a slightly angled position if necessary.

Fig 14: Carefully Bring Transmission Into A Slightly Angled Position If Necessary

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-- Lift the input shaft -1- in direction of -arrow- just enough until it is possible to insert the 3435.

-- Swivel the transmission back into its original horizontal position.

-- Attach the stub shaft to the differential -1- ; this way the differential can be raised in the following work steps.

Fig 15: Attaching Stub Shaft To Differential This Way Differential Can Be Raised

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-- Remove the output shaft for 3rd and 4th gear -2- together with the selector rod -3-.

-- Carefully bring the transmission into a slightly angled position.

Fig 16: Carefully Bring Transmission Into A Slightly Angled Position

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-- Push the output shaft for 1st and 2nd gear -B- all the way up.

-- Then remove the reverse gear output shaft -A-.

CAUTION:

When the transmission is in an angled position, components of the transmission could come loose.

To prevent this, move the transmission back into its original horizontal position.

-- Then remove the 1st and 2nd gear output shaft -B- together with the selector rod -C- from the clutch housing.

-- Remove the input shaft -1- together with the selector rod -2-.

Fig 17: Removing Input Shaft Together With Selector Rod

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-- Remove the differential -3- on the stub shaft.

-- Remove the input shaft seal CLUTCH HOUSING List Item:Input Shaft Seal.

NOTE:

Always replace the grooved ball bearing on the input shaft. Refer to INPUT SHAFT OVERVIEW INPUT SHAFT OVERVIEW .

Installing

Press the new grooved ball bearing onto the input shaft. Refer to INPUT SHAFT OVERVIEW INPUT SHAFT OVERVIEW .
For the correct tightening specifications, refer to TRANSMISSION HOUSING AND GEARSHIFT UNIT OVERVIEW .

-- Mount the T10323 as illustrated.

Fig 18: Mounting T10323

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-- Install the input shaft -1- together and the selector rod for 5th and 6th gears into the clutch housing.

Fig 19: Installing Input Shaft Together And Selector Rod For 5Th And 6Th Gears Into Clutch Housing

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Turn the spindle on the T10323 and lift the input shaft -1- to dimension -a-.

-a- = 15 mm

-- Attach the left stub shaft to the differential -A- ; this way the differential can be raised in the following work steps.

Fig 20: Attaching Left Stub Shaft To Differential

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-- Install the differential.

A second technician is needed to perform the following work.

-- Lift the differential in direction of -arrow- (2nd technician).

-- First place the 1st and 2nd gear input shaft -1- with the gearshift rod -2- in the bearing seat and then move it toward the input shaft -3-.

-- Lift the 1st and 2nd gear output shaft on the gear wheel -arrow A- and swing it toward the input shaft (2nd technician).

Fig 21: Lift 1St And 2Nd Gear Output Shaft On Gear Wheel And Swing It Toward Input Shaft

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-- Guide the reverse gear output shaft -1- under the splines on the gear wheel -arrow A- and place it in the bearing seat -arrow B-.

Turn the spindle on the T10323 and lower the input shaft approximately 10 mm.

-- Install the 3rd and 4th gear output shaft -2- together with the 3rd and 4th gear gearshift rod -1-.

Fig 22: Installation Position, 3rd and 4th Gear Selector Rod:

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The shorter brace -arrow- points to the clutch housing.

-- Remove the left stub shaft -3- from the differential.

-- Lower the input shaft just enough -A- by turning the spindle on the T10323 so that it remains slightly tensioned (lifted approx. 1 mm).

Fig 23: Lower Input Shaft

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-- Place the reverse gear switching rockers -A- into the reverse gear output shaft slide locking collar.

Fig 24: Placing Reverse Gear Switching Rockers Into Reverse Gear Output Shaft Slide Locking Collar

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