Transmission Housing, Servicing

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Special tools and workshop equipment required

Press Piece - Output Shaft Gear/Final Drive Gear: 3002
Press Piece - Trailing Arm: 2010
Puller - Grease Cap: VW637/2
Drive Sleeve: 30-20
Thrust Piece and Sleeve: VW 472
Press Piece - Multiple Use: VW473

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Special tools and workshop equipment required

Press Piece - Bushing: 3118
Press Piece - Bushing - 50mm Diameter: VW432
Seal/Bearing Installer - Sleeve: 32-109
Press Piece - Multiple Use: VW412
Seal/Bearing Installer - Multiple Use: 30-21
Slide Hammer Set: VW771

Special tools and workshop equipment required

Press Piece - Bushing: VW434

Fig 1: Identifying Press Piece - Bushing VW434
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Puller - Two Arm: T10040

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Internal Puller (Kukko 21-3): VAS 251601

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Counter Support: VAS 251 621

Fig 2: Counter Support
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Press Tool: T40323

Output Shaft Cover, Removing

Fig 3: Output Shaft Cover, Removing

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-- Remove the caps, to do so sheer on the center of the cap and remove using the Puller - Grease Cap: VW637/2 as shown.

-- Remove the oil catch tray -1-.

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Install the caps for the output shaft 1

Fig 4: Install the Caps for the Output Shaft -1-

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-- Press in the new end cover with the Press Tool: T40323 .

The oil catch tray must be installed.

CAUTION:

Oil loss due to improper assembly.

The end cover is installed "dry". Never use retaining compound.
Let the end cover be tensioned 10 minutes with the Press Tool: T40323 .

Remove the pinion roller sleeve 1

Fig 5: Remove the pinion roller sleeve -1-

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Beforehand, remove the circlip for the roller sleeve -Item : Circlip.

2 - Internal Puller (Kukko 21-3): VAS 251601

3 - Counter Support: VAS 251 621

Tip:

The transmission cover can be attached to the Transmission Support: VW 353 for this procedure.

Press in the pinion roller sleeve 1

Fig 6: Press in the Pinion Roller Sleeve -1-

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2 - Press Piece - Multiple Use: VW412

3 - Seal/Bearing Installer - Multiple Use: 30-21

Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Sleeve: 30-21 -3-.

-- Then install the roller sleeve circlip -Item : Circlip.

Removing the roller bearing for the output shaft, FWD vehicles

Fig 7: Removing the Roller Bearing for the Output Shaft, FWD Vehicles

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On FWD vehicles the roller bearing for the output shaft is destroyed when removing and must be replaced.

Beforehand, remove the circlip for the roller sleeve -Item : Circlip.

-- Position the Slide Hammer Set - Hook: VW771/37 -3- under the bearing cage and mount rolls -2- and drive out the bearing cage from the bearing shell -1-.

3 - Slide Hammer Set - Hook: VW771/37

4 - Slide Hammer Set: VW771

-- Then remove the bearing shell -1-.

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2 - Puller - Two Arm - Arm: T10040/1

3 - Puller - Two Arm: T10040

4 - Press Piece - Bushing: VW434

5 - Press Piece - Output Shaft Gear/Final Drive Gear: 3002

Pressing in the roller bearing 1 for the output shaft, FWD vehicles

Fig 8: Pressing in the Roller Bearing -1- for the Output Shaft, FWD Vehicles

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-- Support the transmission cover using the Press Piece: VW472/1 -5- directly under the bearing mount.

Position the roller sleeve -1- with the lettered side (larger panel thickness) to the Press Piece - Trailing Arm: 2010 -2-.

2 - Press Piece - Trailing Arm: 2010

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

-- Then install the roller sleeve circlip -Item : Circlip.

Driving out the roller sleeve for the output shaft 1, AWD vehicles

Fig 9: Driving Out the Roller Sleeve for the Output Shaft -1-, AWD Vehicles

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-- If equipped, remove the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

Beforehand, remove the circlip for the roller sleeve -Item : Circlip.

2 - Press Piece - Multiple Use: VW473

Tip:

The transmission cover can be attached to the Transmission Support: VW 353 for this procedure.

Pressing in the output shaft roller sleeve, AWD vehicles

Fig 10: Pressing in the Output Shaft Roller Sleeve, AWD Vehicles

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Position the roller sleeve with the labeled side (larger panel thickness) to the Press Piece - Bushing: 3118 -1-.

1 - Press Piece - Bushing: 3118

2 - Press Piece - Bushing - 50mm Diameter: VW432

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

-- Then install the roller sleeve circlip -Item : Circlip.

-- If equipped, install the seal for the transmission output shaft. Refer to TRANSMISSION OUTPUT SHAFT SEAL, REPLACING .

Drive out the input shaft ball bearing 1

Fig 11: Drive Out the Input Shaft Ball Bearing -1-

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2 - Seal/Bearing Installer - Sleeve: 32-109

Beforehand, remove the ball bearing circlip -Item : Circlip

Tip:

The transmission cover can be attached to the Transmission Support: VW 353 for this procedure.

Pressing in the input shaft ball bearing 1

Fig 12: Pressing in the Input Shaft Ball Bearing -1-

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Ball bearing installation position: the groove -arrow- all around on the ball bearing points downward to the transmission cover.

2 - Seal/Bearing Installer - Sleeve : 32-109

3 - Drive Sleeve: 30-20

4 - Press Piece - Multiple Use: VW412

Install the ball bearing circlip 2 on the drive axle 1

Fig 13: Install the Ball Bearing Circlip -2- on the Drive Axle -1-

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The bevel on the circlip -2- faces away from the ball bearing -1-. The flat side faces the ball bearing.