Transmission, disassembling/assembling: Disassembling

• Mount transmission in repair stand.
• Drain transmission oil.
Fig 1: Mounting Transmission In Repair Stand
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• Remove clutch release lever, clutch release bearing, and release bearing guide sleeve, see Assembly overview - pedal cluster 
• Remove transmission housing cover (-arrow-).
  Fig 2: Removing Transmission Housing Cover

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• Remove 5th gear shift fork (-arrow-).
Fig 3: Removing 5th Gear Shift Fork
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• Remove bolts -A- for synchro-hub and 5th gear. To do this, engage 5th gear (arrow -1-) and 1st gear (arrow -2- and -3-)
  • After engaging both gears, the input shaft and the output shaft are both locked, and the synchro-hub and gear cannot turn. Both bolts can now be loosened.
Fig 4: Removing Bolts -A- For Synchro-Hub And 5th Gear
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• Remove synchro-hub and 5th gear along with needle roller bearing.
  1. - Two-arm puller and hooks e.g. Kukko 20/10 with Matra V/170 hooks
  2. - Hex bolt (M10 x 20)
Fig 5: Removing Synchro-Hub And 5th Gear Along With Needle Roller Bearing
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• Remove 5th gear.
  1. - Two-arm puller and hooks e.g. Kukko 20/10 with Matra V/170 hooks
  2. - Hex bolt (M10 x 20)

     Removal sequence: - Install two-arm puller as shown and center by turning adjustment screw (-arrow-). - Heat gear using VAG 1416 hot air blower, then pull gear off.

  NOTE: When removing the gear, make sure that the hooks do not bend outward. If necessary tighten screw (-arrow-). After removing, check 5th gear for damage.
Fig 6: Removing 5th Gear
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• Remove left-side axle flange.

Transmission without springs behind axle flanges:

• Place chisel or spacer -A- under axle flange and pull flange from differential gears by turning bolt -B- (B = previously removed housing bolt). See Fig 7 .
  NOTE: If the axle flange shaft fails to come out straight, use two spacers -A-, and bolts -B-, positioned opposite each other. Tighten both bolts alternately and evenly.

Fig 7: Removing Left-Side Axle Flange

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Transmission with springs behind axle flanges:

• Remove cone -head bolt before removing axle flange.
• Remove bolts (-arrows-) for reverse idler shaft support bracket.
  • For inside bolt (-left arrow-) use Torx(R) T45 key, 100 mm (4 in.) long
Fig 8: Removing Bolts For Reverse Idler Shaft Support Bracket
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• Shift selector shaft to neutral, then remove bolts (-arrow-).
• Pull selector shaft assembly with cover from transmission housing.
Fig 9: Shifting Selector Shaft To Neutral, And Removing Bolts
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• Remove cover plate -A- and shift fork pivot pins -B- from underside of transmission.
Fig 10: Removing Cover Plate -A- And Shifting Fork Pivot Pins -B- From Underside Of Transmission
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• Remove shift fork pivot pins -A- from upper side of transmission.
• Remove bolts -B- attaching clutch housing to transmission housing in area of differential.
Fig 11: Removing Bolts -B- Attaching Clutch Housing To Transmission Housing In Area Of Differential
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• Remove remaining bolts -A- from inside clutch housing (attaching clutch housing to transmission housing).
  CAUTION: Do not yet remove the four nuts -B- for the output shaft bearing support.
Fig 12: Removing Remaining Bolts -A- From Inside Clutch Housing (Attaching Clutch Housing To Transmission Housing)
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• Remove transmission housing.
• If housing won't separate, carefully pry up all around on the protruding housing flange (-arrows-).
  CAUTION:

  • Pry gently and evenly, alternating on all sides.
  • Be careful to not damage the sealing surfaces.
Fig 13: Removing Transmission Housing
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• Remove shift forks -A- together with selector plates.
• Remove bolt -B- retaining selector mechanism for reverse gear.
Fig 14: Removing Shift Forks -A- Together With Selector Plates
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• Remove nuts (qty: 4) for output shaft bearing support nuts (see ASSEMBLING  , Fig 12 , item -B-)
• Remove reverse gear -A-, input shaft -B- and output shaft -C-, in that order, from clutch housing.
  Fig 15: Removing Order Of Reverse Gear -A-, Input Shaft -B- And Output Shaft -C-, From Clutch Housing

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• Remove right-side axle flange shaft.
  NOTE: Removal procedure for right-side axle flange is the same as the procedure for the left-side axle flange, see ASSEMBLING  .
• Remove differential.