Volkswagen Golf Variant / Jetta. Manual - part 266

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  264  265  266  267   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 266

 

 

screwdriver.

– Remove the cover from the transmission housing.
A - Counter Support , for example Puller - Kukko Counterstay -

22/1-
B - Internal Puller 8 to 12 mm , for example Puller - Kukko Internal

- 12-16mm - 21/01-

Note

Can push through the center of the cover for removing the

cover -1-

Pry the cover -2- carefully off the transmission housing.

Remove the locking ring -C- from the grooved ball bearing on the

input shaft/transmission housing as follows:
– Hold one end of the locking ring secure using the Screwdriver

-A-.

– Pry the other end out of the groove in the grooved ball bearing

in direction of -arrow- using the screwdriver -B-.

– Pry out the rest of the locking ring using the Screwdriver -B-.

– Remove the washer -1- from the transmission housing -2-, if

equipped.

• If transmission is replaced, see if the washer must be installed.

Refer to 

⇒ page 242

 .

11. Transmission, Disassembling and Assembling    

239

the clutch housing.

– Install the Slide Hammer Set - Adapter 40 - VW771/40- into

the threaded hole in the transmission housing.

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

– Remove the transmission housing from the clutch housing in

direction of -arrow- using Slide Hammer Set - Hammer -

VW771/1- .

Note

If necessary, carefully pry up all around and alternating between

sides on protruding flange. Be careful not to damage the sealing

surfaces.

– Remove the washer -1- from the grooved ball bearing -2-, if

equipped.

– If transmission is replaced, see if the washer must be reinstal‐

led. Refer to 

⇒ page 242

 .

– Remove the Separating Tool -A- and the Press Piece - Multiple

Use - VW455- (illustration) or the Press Piece - Front Wish‐

bone - 3160- from the input shaft.

A second technician is needed to help remove the shafts from the

clutch housing.

240

left the output shaft for 1st to 4th gear together with the shift

rods -2- -arrow A-.

– At the same time, the 2nd technician lifts the input, reverse

and output shaft for 5th/6th gear -3- together with the selector

rods out of the clutch housing -arrow B-.

Note

If necessary, differential can be shifted again in clutch housing

after lifting shafts.

– Remove the input shaft seal.

Note

Always replace the grooved ball bearing on the input shaft

-item 6- 

⇒ Item 6 (page 311)

 .

Assembling
• A new grooved ball bearing is pressed onto the input shaft

-item 6- 

⇒ Item 6 (page 311)

 .

– Install the input shaft -1-, the 5th/6th gear and reverse gear

output shaft -2- the gearshift rod -3-, the shift fork -4- and the

reverse shaft -5-.

– Then install the differential -1-.

Note

A second technician is needed to help install the shafts into the

clutch housing.

– Hold the output shaft for 1st through 4th gear -3- and the gear‐

shift rods -4- with the right hand.

– Lift the differential -1- slightly with the left hand.
– Have the second technician lift the input shaft, the 5th/6th gear

output shaft and reverse gear -2- together with the reverse

shaft slightly at the same time.

– Install the 1st to 4th gear output shaft in direction of -arrow-.
• Places of input shaft, output shafts and final drive gear/differ‐

ential must engage.

– Together with a second technician, now displace shafts and

differential in their bearing seats.

11. Transmission, Disassembling and Assembling    

241

on the clutch housing.

Note

The clutch housing is shown in the illustration rotated 180°.

– Install the bolt -A- just far enough until the input shaft starts to

lift.

With Some Transmissions, there are Flattened Sides -A- on the

input Shaft Grooved Ball Bearing and on the Bearing Mount -B-.
Check the input shaft grooved ball bearing and the transmission

housing.

Input Shaft Grooved Ball Bearing and Transmission Housing

No flattened sides on the grooved ball bearing -A- and bearing

mount -B-. Refer to 

⇒ page 242

Flattened sides on the grooved ball bearing -A- and bearing

mount -B-. Refer to

⇒ Fig. ““On Some Transmissions”“ , page 243

From Transmission Build Date 4.10.06 through Approximately

1.21.08
One Washer Each Is Inserted above and below the Input Shaft

Grooved Ball Bearing -item 6- 

⇒ Item 6 (page 311)

 .

Upper washer

Outer circumfer‐

ence

78.6 mm

Lower washer

Outer circumfer‐

ence

85 mm

Measure the Shoulder Above the Grooved Ball Bearing Mount.

Shoulder Above

Grooved Ball Bear‐

ing

Dimension “a”

Upper Washer

Through transmis‐

sion build date

4/9/06

10 mm

no

From transmission

build date 10 04 6

10.7 mm

yes

242

 

 

 

 

 

 

 

Content   ..  264  265  266  267   ..