Contents: All-wheel drive ⬇ Front-wheel drive ⬇
All-wheel drive
1. Unscrew the bolt securing the right shaft with flange (arrow 1) using a special tip (T10107A).
Note: The right flange shaft remains in the bevel gearbox.
2. Unscrew the lower connecting bolts of the gearbox "arrow" and the gearbox with a bevel gear.
Note:
- Some models have a heat-insulating shield (arrow A) installed on the upper side of the corner transmission.
- Access to the screw (arrow B) is from the bottom of the heat shield.
- Access to the screw (arrow C) is from the top side of the heat shield.
3. Carefully move the angular gearbox away from the gearbox; in this case, you must be extremely careful so that it does not fall.
Continuation for all gearboxes
Note: Before disassembling the gearbox, you must first attach the T30109 gearbox mounting tool (VW 353) to the gearbox.
4. Install the eye bolts (3368) on the gearbox housing flange and on the T30109 (VW 353) gearbox bracket as shown in the figure below.
5. Then hook the fastening suspension device MP9-201 (2024 A) onto the screws with a loop (3368).
6. Lift the gearbox using a workshop crane (VAS 6100) onto the assembly stand (MP9-101).
7. Place a container to collect the transmission oil under the gearbox assembly.
8. Drain the transmission oil.
9. Remove the clutch release hydraulic drive slave cylinder with the clutch release bearing (arrows), as shown in the figure below.
Note: Be extremely careful when performing the next step to ensure that the shift control shaft is not blocked by the locking lever (arrow).
10. Adjust the gear shift control shaft to the neutral position.
11. Remove the reverse light switch (1) as shown in the figure below.
12. Unscrew the lock screw (2) shown in the figure below.
13. Unscrew the fastening screws (3).
14. Remove the gear shift control shaft (4) from the gearbox housing.
15. Remove the left shaft with flange.
Front-wheel drive
16. Remove the right drive shaft with flange.
Continued for all models
17. Unscrew the bolts (B) securing the clutch housing to the gearbox housing, as shown in the figure below.
Note: The mounting bolt (arrow) is located outside the flange.
18. Secure the drive shaft with a special sleeve (VW455 (MRZ-412)) through the drive shaft onto the clutch housing, as shown in the figure below.
Note: It may be necessary to use a guide sleeve (3160 (T30102)) instead of the drive sleeve (VW 455 (MRZ-412)) in order to be able to clamp the split puller (A) onto the splines of the drive shaft.
19. Secure the split puller (A) (kukko 17/0) behind the splines of the drive shaft. The rear side of the split puller must fit without a gap against the sleeve (VW 455 (MP3-412)) or the guide sleeve (3160 (T30102)).
20. Remove the retaining ring (A) of the drive shaft cover as shown in the figure below.
21. Pierce the rubber center of the cover (1) with a screwdriver, as shown in the figure below.
22. Carefully remove the cover from the gearbox housing using lever movements of a screwdriver (2).
23. Remove the retaining ring (C) from the radial ball bearing of the input shaft in the gearbox housing as follows:
- Hold one end of the retaining ring with a screwdriver (A).
- Using a lever motion with a screwdriver (B), remove the other end from the groove of the radial ball bearing in the direction of the arrow, as shown in the figure below.
- Remove the entire retaining ring by levering it gradually along its entire perimeter with a screwdriver (B).
24. Unscrew the mounting bolts (A) of the gearbox housing and clutch housing, shown in the figure below.
25. Connect the adapter (s) (MRZ-419/40) into the threaded hole of the gearbox housing.
26. Heat the gearbox housing with a hot air gun in the area where the drive shaft radial ball bearing is installed to 100°C (about 10 minutes.).
27. Using a universal tool (MRZ-419/1), remove the gearbox housing from the clutch housing in the direction of the arrow, as shown in the figure below.
Note: If necessary, carefully release it by using alternate lever movements around the flange perimeter without damaging the sealing contact surfaces.
28. Remove the split puller (A) and sleeve (VW 455 (MP3-412)) or separating sleeve (3160 (T30102)) from the drive shaft. To remove the shafts from the clutch housing, it is necessary to involve a second mechanic.
29. Lift the differential (1) with your left hand. With your right hand, lift the driven shaft from 1st to 4th gear together with the gear shift fork rods (2) (arrow A), as shown in the figure below.
30. At the same time, the second mechanic will remove from the clutch housing (arrow B) the drive shaft, the reverse gear shaft and the driven shaft of the 5th/6th gears and (3) together with the gear shift fork rods.
Note: After lifting the shafts, you can also place the differential back into the clutch housing.