Volkswagen Golf Variant / Jetta. Manual - part 176

 

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Volkswagen Golf Variant / Jetta. Manual - part 176

 

 

⇒ “10 Shift Forks, Disassembling and Assembling”, page 191

 .

10 - Clutch Housing

❑ Servicing. Refer to 

⇒ “8 Transmission Housing and Clutch Housing, Servicing”, page 183

 .

11 - Nut

❑ 25 Nm and 90° additional turn
❑ 4 nuts for the bearing mount
❑ Always replace.

12 - Flange Shaft with Pressure Spring

❑ Removing and installing. Refer to

⇒ “1.4 Seal, Two-Piece Right Flange Shaft Seal and Sleeve, Replacing”, page 256

 or

⇒ “1.5 Seal and Sleeve, One-Piece Right Flange Shaft Seal and Sleeve, Replacing”, page 258

 .

❑ Assembling. Refer to 

⇒ “3 Differential”, page 263

 .

13 - Bolt

❑ 25 Nm

7.6

Assembly Sequence, Transmission

Housing Cover and 5th Gear, Removing

and Installing

⇒ “7.6.1 Transmission Housing Cover and 5th Gear, Removing”,

page 166
⇒ “7.6.2 5th Gear and Transmission Housing Cover, Installing”,

page 170

7.6.1

Transmission Housing Cover and 5th

Gear, Removing

Note

If only 5th has to be removed, follow this procedure:

Gear oil does not need to be drained for this procedure. When

the transmission housing cover is removed, the transmission

must sit with the cover side facing upward.

If it is necessary to remove the transmission housing, follow

the work procedure: Transmission, Disassembling and As‐

sembling. Refer to

⇒ “7.7 Transmission, Assembly Sequence, Disassembling

and Assembling”, page 170

 .

Special tools and workshop equipment required
♦ Holding Plate - VW 309A-
♦ Transmission Support - VW 353-
♦ Bearing/Bushing Installer - Multiple Use - VW 295-
♦ Bearing Driver - Multiple Use - VW 244 B-
♦ Hot Air Blower - VAG1416-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Bracket - Multiple Use - 30-211A-
♦ Bearing Installer - Multiple Use - 32 - 111-

166

draulic Press - Bushing Tool Kit - T10030-

♦ Press Piece - 37mm - VW 416 B-
♦ Puller - Transmission Gears - T10309-
♦ Puller - Two Arm - T10040-
♦ With the Puller - Two Arm w/Thrust Piece - T10040/2A-
♦ Puller - Two Arm Thrust Piece - T10040/3-
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW 433-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Perform the following procedure:
– Remove the clutch release lever and release bearing. Refer

to 

⇒ “2 Clutch Release Mechanism, Servicing”, page 45

 .

• Be careful not to damage the bearing for the input and output

shafts when removing and installing 5th gear.

• When securing the transmission to the Transmission Support

- VW 353- , mount the following tools for support:

Under the Input Shaft:
♦ Bracket - Multiple Use - 30 - 211A-
♦ Bearing Installer - Multiple Use - 32 - 111-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4-
• Input shaft may be supported by Bearing Installer - Multiple

Use - 32 - 111- only at a later time.

Under the Output Shaft Bracket
♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW 433-

– Secure the transmission on the Transmission Support - VW

353- .

7. Transmission, Disassembling and Assembling    

167

– Make sure the Puller - Two Arm w/Thrust Piece - T10040/2A-

can be installed correctly under the 5th gear wheel.

Puller - Two Arm w/Thrust Piece - T10040/2A- cannot be in‐

stalled correctly.

-A-

Puller - Two Arm w/Thrust Piece -

T10040/2A- prematurely touch

the:

♦ Transmission housing wall
♦ The ribbing in the transmission

housing under the 5th gear

wheel

“Combined” removal of the:

“5th gear synchronizer

hub”, “5th gear wheel” and

“transmission housing”.

Refer to

⇒ “7.7 Transmission, As‐

sembly Sequence, Disas‐

sembling and Assembling”,

page 170

 .

The-B-

Puller - Two Arm w/Thrust Piece -

T10040/2A- touch the ribs in the

transmission housing under the

5th gear wheel.

Puller - Two Arm w/Thrust Piece - T10040/2A- can be installed

correctly.

The 5th gear can be removed separately. Refer to

⇒ Fig. ““5th gear, removing separately”“ , page 168

5th gear, removing separately
– Cover the openings in the transmission housing with a cloth.
– Move the shift fork -1- into neutral.
– Remove the bolt -2- with the shift jaw for 5th gear.
– Remove both bolts -arrows- for the pivot pin.
– Remove the pivot pin.
– Remove the 5th gear shift fork.
– It is not necessary to remove the spring -3- and the locking

collar -4-.

168

remove the bolts -A- for the synchronizer hub and for the 5th

gear.

– The input shaft and the output shaft are blocked after both

gears are engaged. The synchronizer hub and the gear wheel

cannot turn. Both bolts can be loosened now.

Note

Remove any locking compound residue still in the threaded holes

using a thread tap if the shafts are not going to be replaced.

Remove 5th gear synchronizer hub together with locking collar

and locking pieces. To do this use the Puller - Transmission Gears

- T10309- .
– Insert the Puller - Transmission Gears - Half Shell - T10309/1-

between the 5th gear wheel -A- and the mount for 5th gear

shift fork -B-.

• The Puller - Transmission Gears - Half Shell - T10309/1- must

be placed under the synchronizer ring.

– Press the Puller into the end position, if necessary.
– Rotate the Puller - Transmission Gears - Half Shell - T10309/1-

to the opposite side in direction of the -arrow-.

– Install the Puller - Transmission Gears - Threaded Insert -

T10309/3- in the Puller - Transmission Gears - Half Shell .

– Install the second Puller - Transmission Gears - Half Shell -

T10309/1- and put the Puller - Transmission Gears - Tube -

T10309/2- on the tool.

– Check synchronizer hub after pulling for damage.
– Replace the 5th gear synchronizer ring
– Remove 5th gear selector gear with needle bearing.

7. Transmission, Disassembling and Assembling    

169

 

 

 

 

 

 

 

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