Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 585
– Remove the third bolt -arrow- from the reverse shaft support.
– Transmission on vehicles with Stop/Start system: remove the
Transmission Neutral Position Sensor - G701- -arrow-.
– Move the gearshift shaft into neutral and remove the gearshift
shaft with the gearshift cover. Remove the bolts -arrows- and
pull the gearshift shaft out of the transmission housing.
– Remove the cover -A- and pivot pin -B- on the bottom of the
transmission.
– Remove pivot pins -A- on top side of transmission and bolts
-B- for transmission housing to clutch housing in area of dif‐
ferential.
– Remove the bolts -A- that connect the clutch and transmission
housing.
Note
Do not remove the nuts -B- for the bearing mount on the output
shaft.
– Remove both flange shafts.
– Remove the flange shafts with the springs, thrust washers and
tapered rings.
Remove the Following Components Together with the Transmis‐
sion Housing:
♦ 5th Gear Synchronizer Hub
♦ 5th Gear Wheel
• Both Spacer Plate - T10408/3- must be attached to the 5th
gear wheel.
• The Spacer Plate must be located above the 2 ribs on the
housing, opposite each other -arrows-.
Note
♦
There is a needle bearing under the 5th gear wheel.
♦
Secure the Straps so that the needle bearing does not touch
the 5th gear wheel when removing the transmission housing.
Use the Puller - Transmission Gears - T10408- with the Following
Special Tools:
♦ Puller - Transmission Gears - Thrust Piece - T10408/2-
♦ Spacer Plate - T10408/3-
♦ Kukko 18/1 puller (quantity: 2)
– Install the Puller - Transmission Gears - T10408- in the threa‐
ded holes in the transmission housing cover using the bolts
-A-.
A - M7 x 35 Hex Bolts with Washers
Tightening specification 18 Nm
– Place the Puller - Transmission Gears - Thrust Piece -
T10408/2- on the shaft.
– Install Kukko puller 18/1 -A-.
– Remove the 5th gear synchronizer hub, the 5th gear wheel
and the transmission housing by tightening the spindles -A-
(approximately
1
/2 turn), alternating from side to side.
– Warm the 5th gear wheel slightly using the Hot Air Blower -
VAG1416- .
– Remove the nuts -B- from the bearing mount/output shaft.
– Remove the shift forks -A- together with the gearshift rails.
– Remove the gearshift mechanism/reverse gear -B-.
– Remove the reverse gear -A-, the input shaft -B- and the output
shaft -C-, one after the other, from the clutch housing.
– Remove the differential.
Assembling the Transmission
– Install the differential.
– Replace the sealing rings -arrows- for output shaft bearing
mount after removing.
Note
The illustration only shows 3 of the 4 seals.
– Insert output shaft -1- and output shaft -2- together.
– Tighten the nuts for the bearing mount / output shaft.
– Install the reverse gear wheel -3- on the needle bearing inside
the clutch housing.
Shoulder -arrow- faces away from clutch housing.
– Make sure the reverse shaft -4- is complete. Refer to
⇒ “3.2 Reverse Shaft, Disassembling and Assembling”,
. Do not mount the support on the reverse shaft.
– Install the reverse shaft into the clutch housing.
– Clean all threaded holes in reverse shaft supports of locking
compound; cleaning can be done with a thread tap.
– Mount the reverse shaft support.
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