Volkswagen Golf Variant / Jetta. Manual - part 265

 

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Volkswagen Golf Variant / Jetta. Manual - part 265

 

 

⇒ Item 6 (page 311)

 .

8 - Reverse Shaft

❑ With a thrust washer

9 - Thrust Washer
10 - Bleeder

❑ Connect with clutch slave cylinder

11 - Clutch Housing

❑ Servicing. Refer to 

⇒ “13 Clutch Housing, Servicing”, page 269

 .

12 - Input Shaft Seal

❑ Replacing. Refer to 

⇒ “2.4 Input Shaft Seal, Replacing”, page 55

 .

13 - O-Ring

❑ Install on the line connection
❑ Coat with brake fluid before installing

14 - Clutch Slave Cylinder with Release Bearing
15 - Bolt

❑ Quantity: 3
❑ Replace after removing
❑ Removing and installing -item 4- 

⇒ Item 4 (page 50)

 .

16 - Bolt

❑ Removing and installing -item 13- 

⇒ Item 13 (page 401)

 .

17 - Bolt

❑ 40 Nm + 90°
❑ Quantity: 4
❑ Replace after removing

18 - Bevel Box

❑ Seals, flange shaft bearing and output flange bearing inside the bevel box. Refer to

⇒ “3 Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box”,

page 377

 .

19 - Differential

❑ Disassembling and assembling. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399

 .

11.8

Assembly Sequence, Transmission

»without« a Securing Ring -A- for the

Metal Cover for the Input Shaft

Special tools and workshop equipment required
♦ Holding Plate - VW309A-
♦ Holding Fixture - VW313-
♦ Transmission Support - VW353-

11. Transmission, Disassembling and Assembling    

235

Wishbone - 3160-

♦ Slide Hammer Set - VW771-
♦ Puller - Kukko Internal - 12-16mm - 21/1-
♦ Puller - Kukko Quick Action Separating Tool - 5-60mm - 17/0-
♦ Puller - Kukko Counterstay - 22/1-
♦ Bracket - Multiple Use - 30-211A-
♦ Seal Installer - Crankshaft - T10042-
♦ Locking Sleeve Drift - T10169-
♦ or Locking Sleeve Drift - T10362-

⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

♦ Seal Installer - Driveshaft - T40008-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Hot Air Blower - VAG1416-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Socket And Extended Bit - T10107A-
♦ Sealing Compound - AMV 188 200 03-
Disassembling
– Attach the transmission to the assembly stand with bolts

-arrows-.

Note

If one of the fastening holes does not touch the Transmission

Support place shims between the hole and the Transmission

Support .

– Turn the transmission in the assembly stand so that the drain

plug is facing down.

– Place the Drip Tray underneath.
– Drain gear oil from manual transmission.

AWD Transmission
– Remove the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

– Remove the four bolts -arrows- (only three bolts are shown in

the illustration) that attach the bevel box to the transmission.

– Carefully press bevel box off manual transmission while pro‐

tecting it against falling through.

Transmission for FWD

236

flange shaft).

Continuation for All

– Remove the clutch slave cylinder with the release bearing

-arrows-.

Make Sure the Gearshift Shaft Is Not Blocked by the Lock Elbow

-arrow-.
– Move the gearshift shaft into neutral.
– Remove the Back-Up Lamp Switch - F4- -1-.
– Remove the locking bolt -2-.
– Then remove the bolts -3-.
– Remove selector shaft with shift cover -4- from transmission

housing.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing in direction of -arrow- so that the gearshift

shaft -1- does not touch the securing bushing -2- when removing.

11. Transmission, Disassembling and Assembling    

237

into the flange and counterhold the flange using a pry bar.

– Remove the left flange shaft and the pressure spring.

– Remove the bolts -B- that connect the clutch housing to the

transmission housing.

Note

One bolt -arrow- is located outside of the bolting flange.

– Secure the input shaft as follows:
The Stub Shaft Splines on the Input Shaft has Different Lengths

on the Transmission.

– Either place the Press Piece - Multiple Use - VW455- over the

input shaft on the clutch housing.

– Or place the Press Piece - Front Wishbone - 3160- over the

input shaft on the clutch housing.

– Tension the Separating Tool -A-, for example Puller - Kukko

Quick Action Separating Tool - 5-60mm - 17/0- , tightly behind

the splines on the input shaft.

The back of the Puller - Kukko Quick Action Separating Tool -

5-60mm - 17/0- must touch the Press Piece - Multiple Use -

VW455- or the Press Piece - Front Wishbone - 3160- free-of-play.

238

 

 

 

 

 

 

 

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