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Transmission housing,
servicing
Special tools, testers and auxiliary items
required:

Multi-purpose tool 771/1 with attachment

771/15

Mandrel 2062

Press tool VW 408 A

Tube VW 423

Thrust pad VW 454

Extractor lever VW 681

Guide pin 10-15

Drift sleeve 30-100

Mandrel 30-505

Installing tool 40-503

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Internal puller 14.5-18.5 mm e.g. Kukko 21/2

Internal puller 30-37 mm e.g. Kukko 21/5

Depth gauge

Assembly sleeve, Part No. 01E 311 120

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Note:
Refer to general repair instructions Page 00-
11 .
Adjustments are required when replacing
components marked 1) Page 39-37 ,
adjustment overview.
1 - Seal
For drive flange
Pulling out Fig. 1
Driving in Fig. 2
Fill space between sealing lips with sealing
grease G52 128 A1.
Replacing with transmission installed
Page 39-1
2 - Final drive cover 1)

3 - O-ring
For cover for final drive
Always replace

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4 - Shim "S1"
Note thickness
Adjustment overview Page 39-37
5 - Outer race for large tapered roller bearing
1)

For differential
Driving out and driving in Page 39-32
6 - Outer race for small tapered roller bearing
1)

For differential
Driving out and driving in Page 39-31
7 - Shim "S2"
Note thickness
Adjustment overview Page 39-37

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8 - Seal
For input shaft
Prying out Fig. 3
Driving in Fig. 5
Always replace when removing input shaft
Replacing when transmission is not
disassembled Fig. 4 and Fig. 5
9 - Oil drain plug, 40 Nm
10 - Ball sleeve
For selector shaft
Replace
Pulling out Fig. 6
Driving in Fig. 7
11 - Ball sleeves
For selector shafts
Replace
Pulling out, as - 10 - Fig. 6
Driving in, as - 10 - Fig. 7

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12 - Circlip
Installation position: eyes facing up
13 - Switch for back-up lights, 20 Nm
14 - O-ring
For cover for selector shaft
Always replace
15 - Cover for selector shaft
Removing Page 34-59
Installing Page 34-85
16 - Ball stud, 20 Nm
For connecting rod
17 - Outer race for large tapered roller bearing
1)

For drive pinion

Pulling out Fig. 1 , Page 35-22
Pressing in Fig. 2 , Page 35-22 and
Fig. 3 , Page 35-23

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18 - Circlip
Removing Fig. 16
19 - Shim "S3"
Note thickness
Adjustment overview Page 39-37
20 - Needle bearing
For input shaft
Pulling out Fig. 13
Driving in Fig. 14
Measuring insertion depth Fig. 15
21 - Locking bolt
For selector shaft
Removing Page 34-59
Installing Page 34-85
Tightening torques: For aluminium bolt =
50 Nm, and for steel bolt = 70 Nm

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22 - Breather
Clip cap on
For transmission with sleeve insertion
depth of sleeve Fig. 11
For transmission with with additional
breather hose Fig. 12
23 - Trunnion bolt, 40 Nm
For push rod
24 - Seal for selector shaft
Can be replaced when transmission is
removed but not disassembled
Always replace
Pulling out Fig. 8
Driving in Fig. 9
Always use assembly sleeve for installing
Fig. 10
25 - Transmission housing 1)

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26 - Magnet
Clean
When replacing transmission housing drive
in with e.g. press tool VW 408 A
27 - Sender for speedometer -G22-
Replacing Page 39-4
28 - O-ring
Always replace
29 - Oil filler plug, 40 Nm

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Fig. 1 Pulling out seal for drive flange

Note:
Illustrated, removing oil seal on right-hand side.
Procedure for removing oil seal on left and right-hand sides is
identical.

Fig. 2 Driving in seal for drive flange

- Fill space between sealing lip and dust lip with sealing grease G52 128
A1.
Pressing-in depth (factory): 5.5 mm
Pressing-in depth when re-installing a used drive flange (repairs): 6.5
mm

Note:
Illustrated, installing oil seal on right-hand side.
Procedure for installing oil seal on left and right-hand sides is identical.

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Fig. 3 Prying out seal for input shaft when transmission is

dismantled
- Pry out seal carefully with VW 681.

Fig. 4 Removing seal for input shaft when transmission is not

dismantled
- Pry out seal carefully with a screwdriver.

Note:

Do not damage bearing surface on input shaft for shaft seal.

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Fig. 5 Driving in seal for input shaft

- Fill space between sealing lip and dust lip of new seal for input shaft
with sealing grease G52 128 A1.
- Fit a thin protective hose tightly over splines of input shaft.
- Drive in seal for input shaft.
Pressing-in depth (factory): 3.5 mm
Pressing-in depth when re-installing a used input shaft (repairs): 4.5
mm
- Remove protective hose.

Fig. 6 Pulling out ball sleeve

- Remove circlip.
A - Internal puller 14.5-18.5 mm, e.g. Kukko 21/2

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Fig. 7 Driving in ball sleeve

- Drive in onto stop.

Fig. 8 Pulling out seal for selector shaft

Note:

With transmission removed but not disassembled, carefully pry out seal
without damaging the shaft with a screwdriver.

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Fig. 9 Driving in seal for selector shaft

Selector shaft installed or removed
- Fill space between sealing lip and dust lip with sealing grease G52 128
A1.
- Pull assembly sleeve onto selector shaft Fig. 10 .
- Drive seal into housing onto stop.

Fig. 10 Installing seal and selector shaft with assembly sleeve

- To avoid damaging seal -C- always use assembly sleeve -A-, Part No.
01E 311 120, to install seal or selector shaft.

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Fig. 11 Insertion depth of breather sleeve for transmissions

without breather hose
Dimension a = 21 mm

Fig. 12 Breather for transmission with breather hose

1 - Transmission

2 - Sleeve: drive in onto stop

3 - Pipe: drive in onto stop

4 - Clamp

5 - Hose

6 - Breather pipe

7 - Retaining clip

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Fig. 13 Pulling needle bearing out of transmission housing

A - Internal puller 30-37 mm, e.g. Kukko 21/5

Fig. 14 Driving needle bearing into transmission housing

Installation position: inscription on bearing faces tool
Insertion depth Fig. 15

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Fig. 15 Insertion depth of needle bearing

Dimension a = 105 mm

Fig. 16 Removing circlip

- Lift circlip out of groove by turning one end of circlip with a screwdriver
-A-.
- Secure this end with a screwdriver -B-.
- Pry circlip out further by repositioning screwdriver -A-.

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Fig. 17 Installation position of oil baffle plate for transmission DSY

1 - Breather
2 - Oil baffle plate
3 - Selector shaft

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Selector shaft (complete), disassembling

and assembling

1 - Selector cylinder
2 - Roll pin
Drive out and drive in flush Fig. 1
3 - Selector shaft
Driving out Fig. 2
Driving in Fig. 3
Installation position: flat (arrow) and
selector finger - 4 - face in same direction
4 - Selector finger
Observe installation position to - 3 -
5 - Cam for reversing light switch

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Fig. 1 Driving out and driving in roll pin flush

A - Drift
B - Vice clamps

Fig. 2 Driving out selector shaft

A - Drift
B - Vice clamps

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Fig. 3 Driving in selector shaft

A - Wooden block

Note:
Bring holes into alignment.
Flat on selector shaft and selector finger point in same direction.

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