Volkswagen Golf Variant / Jetta. Manual - part 526

 

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Volkswagen Golf Variant / Jetta. Manual - part 526

 

 

bolts -A-.

– Remove the shift mechanism hex collar bolt nut -B- (secures

reverse gear).

– Remove bolts for left flange shaft -C-, by installing two bolts

into the flange and counter-holding flange shaft using a tire

iron.

– Remove the flange shaft -C- with spring.
– Turn the transmission in mounting bracket and the clutch

housing upward.

– Remove the securing bolts that secure transmission housing

from inside clutch housing.

– Carefully pry off the clutch housing all around while alternating

sides on protruding flange, do not damage sealing surfaces.

Note

Do not tilt clutch housing.

The roller bearing and the bearing seat on the input and output

shafts must not be damaged.

– Remove the differential -A- from the transmission housing.

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

Transmission Neutral Position Sensor - G701- -arrow-.

120

shaft into neutral. Remove the bolts -arrows- and pull the

gearshift shaft out of the transmission housing.

– Remove the mounting pins -B- from the top of the transmis‐

sion.

– Remove the Back-Up Lamp Switch - F4- -C-.

– Remove the bolt -A- for securing the reverse drive gear axle.
– Remove the mounting pins -B- on bottom side of transmission.

Note

Do not remove the sealing cap -arrow- to disassemble the trans‐

mission.

– Remove the input and output shafts together with bearing

mount, shift mechanism (shift forks) and reverse gear.

Note

Position the transmission housing so as not to damage the

fitting sleeves.

When removing the components, have a 2nd technician there

to keep them from falling down.

– Remove the input and output shafts from the bearing mount

with grooved ball bearing. Refer to

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bear‐

ing”“ , page 152

 .

6.6.2

Transmission, Assembling

Special tools and workshop equipment required
♦ Holding Fixture - VW313-
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW412-
♦ Gearbox Support - 3221- (modifying. Refer to 

⇒ page 118

 ) or

♦ Gearbox Support - 3221A-
♦ Guide Pin - T10079-
♦ Not needed: Press Piece - 31.5mm - VW418A-
♦ Press Piece - Rod - VW407-
♦ Bearing Installer - Wheel Bearing/Ball Bearing - 3074-
♦ Press Piece - T10080-

6. Transmission, Disassembling and Assembling    

121

shaft with selector cover, input shaft, output shaft, differential and

selector mechanism.

Note

Install the bearing mount with grooved ball bearing onto the

input and output shafts. Refer to 

⇒ page 155

 .

Install the 5th gear drive gear needle bearing sleeve onto the

input shaft. Refer to

⇒ Fig. ““Install the 5th Gear Needle Bearing Sleeve -A-.”“ ,

page 156

 .

– Place assembled input shaft -2-, output shaft -1- with bearing

mount/grooved ball bearing in Press Piece - T10085- .

– Install the shift mechanism (shift forks) -4- into the shaft locking

collars.

– Install the reverse gear axle -3- with reverse gear.
– Attach the Guide Pin - T10079- to the threaded pins (secures

reverse gear) -arrow-.

– Install the components into the transmission housing. Guide

the Guide Pin - T10079- through the hole for the securing the

gearshift mechanism in the transmission housing.

– Remove the Guide Pin - T10079- .
Note the Following before Pressing In:

122

drive gear.

♦ Check the splines on the output shaft dimension -a-.

Note

Due to the varying spline height, the output shafts of individual

transmissions have different -a- lengths.

So that the output shaft and input shaft are always pressed in

the same if necessary a Press Piece - Block - Washer -

T10083/1- (3 mm thick) must be placed on the input shaft.

For this reason the splines on the output shaft dimension -a-

must be measured.

Dimension -a- = 30.6 mm

Place the Press Piece - Block - Washer - T10083/1- on the driv‐

eshaft ⇒ next illustration.

Place the Press Piece - Block - Washer - T10083/1- on both the

input shaft and the bearing mount and press in with the input and

output shaft until stop.

Carefully pressing bearing mount in together with input and output

shaft as far as stop.

6. Transmission, Disassembling and Assembling    

123

 

 

 

 

 

 

 

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