Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 512

– Or place the -3160- over the input shaft on the clutch housing.
– Tension the Separating Tool - 5-60mm -A-, for example

-17/0- , tightly behind the splines on the input shaft.

The back of the Separating Tool - 5-60mm must touch the -

VW455- or the -3160- free-of-play.

Note

Metal and plastic covers are installed for the input shaft.

The locking ring -A- has been discontinued together with the plas‐

tic cover for the input shaft.
♦ -I- = Steel cover for the input shaft with locking ring -A-
♦ -II- = Plastic cover for the input shaft without locking ring

Metal Cover
– Remove the cap/input shaft circlip -A-.

– Pierce the rubber piece into the center of the cover -C- using

a Screwdriver .

Caution

There is a risk of damaging the components underneath the

cover.

– Remove the cover from the transmission housing.
A - Counter Support , for example -22/1-
B - Internal Puller 8 to 12 mm , for example -21/1-

Note

Pry the cap -1- off with a screwdriver -2-.

Plastic Cover
Carefully remove all tabs -A-. Do not damage the transmission

housing when doing so.

– Remove the cap -A-.
• Make sure the individual parts of the cover are removed, if

necessary.

Continuation for All
Remove the locking ring -C- from the grooved ball bearing on the

input shaft/transmission housing as follows:
– Hold one end of the locking ring secure with the Screwdriver

-A-.

– Pry the other end out of the groove in the grooved ball bearing

in direction of -arrow- using the Screwdriver -B-.

– Pry out the rest of the locking ring using the screwdriver -B-.

– Remove the bolts -A- that attach the transmission housing to

the clutch housing.

– Install -VW771/40- into the threaded hole in the transmission

housing.

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, -VAG1416- .

– Remove the transmission housing from the clutch housing in

direction of -arrow- using -VW771/40- .

Note

Pry off the transmission housing carefully at the protruding braces

using a pry lever and alternating from side to side. Do not damage

sealing surface.

– Remove the Separating Tool -A- and the Press Piece - Multiple

Use VW455 or the -3160- from the input shaft.

A second technician is needed to help remove the shafts from the

clutch housing.

– Lift the differential -1- with the left hand. With the right hand,

lift the output shaft for 1st to 4th gear together with the shift

lever rods -2- -arrow A-.

– At the same time, the second technician lifts the input-, re‐

verse- and output shafts for 5th/6th gear and reverse gear

-3- together with the shift lever rod out of the clutch housing

-arrow B-.

Note

If necessary, differential can be shifted again in clutch housing

after lifting shafts.

– Remove the input shaft seal.

Note

Replace grooved ball bearing on drive axle after removing. Refer

to

⇒ “1.1 Overview - Input Shaft”, page 157

.

Assembling the Transmission

• A new grooved ball bearing is pressed onto the input shaft.

Refer to

⇒ “1.1 Overview - Input Shaft”, page 157

.

• The reverse gear shift fork -1- is placed on the 5th and 6th gear

shift lever rod -2-. Refer to

⇒ page 123

.

– Install the input shaft -1-, the 5th/6th gear output shaft -2- and

the 5th/6th gear shift lever rod -3-, the reverse gear shift fork

-4- and reverse shaft -5-.

• The shift jaw -arrow A- on the reverse gear shift fork faces the

outside of the transmission. The shift jaw -arrow B- on the 5th/

6th gear shift lever rod must face toward the inside of the

transmission.