Disassembling and Assembling Gear Housing - GT2

345237 Disassembling and Assembling Gear Housing - GT2


Tools










Overview










Disassembling gear housing

1. Remove transmission cover.

2. Disassemble front gear set.

3. Remove gear housing.


Disassembling gearshift

1. Unscrew screw plug (no. 12 in overview) and remove compression spring and locking pin (no. 13 and 14 in overview).

2. Remove circlip (no. 15 in overview) with screwdriver.

3. Remove shift catch to the inside with roller (no. 17 and 18 in overview).

4. Pull shift lever outwards with rubber washer (no. 16 and 21 in overview).

5. Lever out shaft seal (no. 19 in overview) with screwdriver.





6. Drive out bearing sleeves (no. 20 in overview) with special tool pressure piece 9648.

Removing outer bearing race
1. Remove snap ring (no. 2 or 5 in overview) with screwdriver.





2. Drive out outer bearing race (no. 3 or 6 in overview) with special tool pressure piece P 254 b or special tool pressure piece P 254 a and special tool pull-in tool and extractor P 254.

3. Remove snap ring (no. 4 or 7 in overview) from groove in outer bearing race.

Removing ball sleeves





1. Knock out ball sleeve (no. 8 to 11 in overview) outwards with internal puller 14 - 20 mm and special tool striker VW 771.

Removing screw plug
1. Unscrew screw plug (no. 1 in overview) with Allen key.


Assembling gear housing

1. Refit gear housing on transmission case and screw in screws.
Tightening torque: 23 Nm (17 ft. lbs.)

2. Assemble front gear set.

3. Fit front transmission case cover.

Assembling gearshift

1. Drive in bearing sleeves (no. 20 in overview) with special tool pressure piece 9648/1.

2. Drive in shaft seal (no. 19 in overview) with special tool pressure piece 9649/1. Before doing this, fill the space between the dust and sealing lips with grease (e.g. Liqui Moly).

3. Insert shift lever from outside with rubber washer (no. 16 and 20 in overview).

4. Push shift catch with roller (no. 17 and 18 in overview) onto shift lever from the inside.

5. Push on circlip (no. 15 in overview).

6. Insert locking pin, compression spring and screw plug (no. 14, 13 and 12 in overview)
Tightening torque: 20 Nm (15 ft. lbs.)

Installing outer bearing race

1. Insert snap rings (no. 4 or 7 in overview) into the groove of the outer bearing race.

2. Drive in outer bearing race (no. 3 or 6 in overview) with special tool pressure piece P 254 b or special tool pressure piece P 254 a and special tool pull-in tool and extractor P 254 from the outside.

3. Insert snap rings (no. 2 or 5 in overview).

Installing ball sleeves

1. Drive in ball sleeves (no. 9 and 10 in overview) with special tool pressure piece 9648. Use short side (installation depth 0.6 mm) of the special tool.

2. Drive in ball sleeves (no. 8 and 11 in overview) with special tool pressure piece 9648. Use long side (installation depth 1.4 mm) of the special tool.

Installing screw plug

1. Screw in plug screw (no. 1 in overview).
Tightening torque: 30 Nm (22 ft. lbs.)


Tightening Torques