Disassembling and Assembling Transmission Housing

Disassembling and assembling transmission housing
Tools

















Preliminary work

1. Remove transmission.





2. Tighten the transmission using engine support 9589 or engine and gear support VW 540 at the assembly support.
3. Drain transmission oil.
4. Disassemble the transmission.

Disassembling transmission housing





1. If the parts marked are replaced, re-adjustment is necessary.





Instructions for disassembling transmission housing









1. Pull out taper roller bearing outer ring -8- using pressure piece 3128 and bridge vw 771/9.





2. Press out needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-202. -A= Schraube M10x135-

Assembling transmission housing





2. If the parts marked are replaced, re-adjustment is necessary.








Instructions for assembling transmission housing









1. Press in needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-202 (do not drive in!). Measurement from top edge of rule to top edge of needle-roller bearing -a = 39.5 � 0.3 mm-.





2. Rim offset of sleeve for transmission vent. -a = 27 ± 0.5 mm.
3. Installation instructions for lock for 5th gear and reverse
- Insert spring -- into plastic bushing -1- and press lightly to turn it anti-clockwise until the spring engages at the base of the plastic part.
- Position the bushing -3- on the spring in such a way that the bent end of the spring is located in the groove provided.
- Press the spring together with the bushing -3-, twist it on by turning it once anti-clockwise (to the left) until the lug of the bushing -3- is located above the groove in the plastic bushing.
- Press the lug of the bushing -3- as far as it will go into the groove of the plastic bushing -1-.
- Turn the bushing -3- clockwise (to the right) and let it go.
- Bushing -3-pops into assembly end position.





1 - Plastic bushing
2 - O-ring
3 - Bushing with lock for 5th gear and reverse
4 - Spring





- The lug -A- of the bushing for 5th gear and reverse must always be positioned as far as it will go opposite the groove -B- of the plastic bushing.

Subsequent work

1. Assemble transmission.
2. Fill with transmission oil.
3. Remove transmission from assembly support.
4. Install transmission.