Volkswagen Golf Variant / Jetta. Manual - part 268

 

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Volkswagen Golf Variant / Jetta. Manual - part 268

 

 

washer and the tapered ring.

Transmission for FWD
– Install the right flange shaft and pressure spring, the thrust

washer and the tapered ring.

AWD Transmission
Install the bevel box into the manual transmission as follows:
– With a manual transmission, lubricate the differential splines

with Grease for Clutch Disc Shaft Splines - G 000 100- .

– Slide on bevel box completely on manual transmission, while

doing this, join splines of input shaft/bevel box centrally with

differential.

– Bring the right driveshaft splines and the differential bevel gear

into alignment. Rotate the flange shaft if necessary.

– With proper tooth position and central guiding, bevel box slips

up to stop against manual transmission.

Note

Do not pull bevel box with mounting bolts against the transmis‐

sion. Otherwise bevel box is canted and mounting eyelets can

break off.

– Tighten the 4 bevel box connecting bolts -arrows- (only 3 are

shown in illustration) at manual transmission.

– Tighten the bolt for the right flange shaft with the Socket

Wrench for example Socket And Extended Bit - T10107A- .

11.9

Assembly Sequence: I = Transmission

»with« a Securing Ring -A- for the Metal

Cover for the Input Shaft; II = Transmis‐

sion with Plastic Cover for Input Shaft

The Plastic Cover for the Input Shaft Does Not Require the Se‐

curing Ring -A-.

Special tools and workshop equipment required
♦ Holding Plate - VW309A-

11. Transmission, Disassembling and Assembling    

247

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 - Kukko 22/1-
♦ Bracket - Multiple Use - 30-211A-
♦ Seal Installer - Drive Flange - T10143- or Seal Installer - Out‐

put Shaft Oil Seal - T10180-

♦ 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.

248

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

– Remove the right flange shaft (the illustration shows the left

flange shaft).

Continuation for All

– Remove the clutch slave cylinder with the release bearing

-arrows-.

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

Transmission Neutral Position Sensor - G701- -arrow-.

11. Transmission, Disassembling and Assembling    

249

-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.

– Remove the left flange shaft bolt. To do this, install two bolts

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.

250

 

 

 

 

 

 

 

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