Volkswagen Golf Variant / Jetta. Manual - part 269

 

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Volkswagen Golf Variant / Jetta. Manual - part 269

 

 

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 - Kukko 17/0- , tightly

behind the splines on the input shaft.

The back of the Separating Tool - 5-60mm must touch the Press

Piece - Multiple Use - VW455- or the Press Piece - Front Wish‐

bone - 3160- free-of-play.

Metal Cover
– Remove the cap/input shaft circlip -A-.

– Pierce the rubber piece in the center of the cover -C- using a

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 - 21/1-

11. Transmission, Disassembling and Assembling    

251

housing when doing so.

– Pry out the cover.
• Ensure that the individual cover parts are removed as neces‐

sary.

Continuation for All

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 bolts -A- that attach the transmission housing to

the clutch housing.

252

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 Separating Tool -A- and the Press Piece - Multiple

Use VW455 or the Press Piece - Front Wishbone - 3160- from

the input shaft.

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

clutch housing.

– Lift the differential -1- with the left hand. With the right hand,

lift the output shaft for 1st to 4th gear together with the gearshift

rods -2- -arrow A-.

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

and output shaft for 5th/6th gear and reverse 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)

 .

11. Transmission, Disassembling and Assembling    

253

output shaft -2-, the gearshift rod -3-, the reverse gear shift

fork -4- and reverse shaft -5-.

Pay Attention to the Different Bearing for the Reverse Gear Shift

Fork.

The Reverse Gear Shift Fork -1- is Mounted on the Axle -2- behind

the 5th and 6th Gear Shift Rod -3-.

The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod

with the 5th and 6th Gear Shift Fork -2-.
Continuation for All

254

 

 

 

 

 

 

 

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