Volkswagen Golf Variant / Jetta. Manual - part 177

 

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Volkswagen Golf Variant / Jetta. Manual - part 177

 

 

17 mm

Note

When remove drive gear, make sure the hook does not bend

outward. Check the 5th gear for damage.

Warm the gear slightly if necessary using the Hot Air Blower

VAG1416 - VAG1416- .

7.6.2

5th Gear and Transmission Housing

Cover, Installing

5th Gear, Installing. Refer to

⇒ “7.7.3 5th Gear, Installing”, page 179

 .

– Install the transmission housing cover and tighten the bolts to

the specification. Refer to

⇒ “7.3 Cover for Transmission Housing and 5th Gear, Remov‐

ing and Installing”, page 162

 .

– Install the clutch release lever and release the bearing. Refer

to 

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

 .

– Fill the transmission fluid. Refer to 

⇒ page 95

 .

7.7

Transmission, Assembly Sequence,

Disassembling and Assembling

⇒ “7.7.1 Transmission, Disassembling Completely”, page 170
⇒ “7.7.2 Assembling the Transmission”, page 176
⇒ “7.7.3 5th Gear, Installing”, page 179

7.7.1

Transmission, Disassembling Com‐

pletely

Removing and Installing Transmission Housing Cover, Transmis‐

sion Housing, Selector Shaft with Selector Cover, Input Shaft,

Output Shaft, Differential and Selector Mechanism.
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-
♦ Assembly Tool Kit - Press Piece 2 - T10030/4- from the Hy‐

draulic Press - Bushing Tool Kit - T10030-

♦ Press Piece - 37mm - VW 416 B-
♦ Puller - Transmission Gears - T10408-

170

- Transmission Gears - T10408- )

♦ Support Bridge - T10323-
♦ Rear Wheel Bearing Kit - Piece 7 - 3253/7-
♦ Press Piece - Multiple Use - VW 433-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -

Kukko 18/1- (quantity 2)

♦ Inductive Heater - VAS6414-
♦ Sealant - AMV 188 200 03-
♦ Stud bolt M8 x 100 mm
Perform the following procedure:
– Secure the transmission on the Transmission Support - VW

353- .

– Place the Drip Tray underneath.
– Open the oil filler plug and the oil drain plug.
– Drain the transmission fluid.
– Remove the clutch release lever, the release bearing and the

guide sleeve. 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-
– Secure the bolt on the Bracket - Multiple Use - 30 - 211A- with

the nut -A-.

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

7. Transmission, Disassembling and Assembling    

171

Remove the 5th gear shift fork as follows:
– 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-.

– Engage 5th gear -arrow 1- and 1st gear -arrows 2 and 3- to

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 both bolts -arrows- for the reverse shaft support.

172

– Transmission on vehicles with Stop/Start system: remove the

Transmission Neutral Position Sensor - G701- -arrow-.

– Move the gearshift shaft into neutral and remove the gearshift

shaft with the gearshift cover. Remove the bolts -arrows- and

pull the gearshift shaft out of the transmission housing.

– Remove the cover -A- and pivot pin -B- on the bottom of the

transmission.

7. Transmission, Disassembling and Assembling    

173

 

 

 

 

 

 

 

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