Disassembling the gearbox (VW Passat B4)

Clean the gearbox, drain the oil from the gearbox housing by unscrewing the oil drain plug (Fig. 4-14), and install it on a disassembly stand. Remove the driven shaft-gear of the speedometer drive.



Remove the clutch release fork and the clutch release bearing. Remove the clutch release bearing guide sleeve and take out the oil seal from it. Remove the rear gearbox cover. On a five-speed gearbox, unscrew the two 5th gear fork mounting bolts and the carrier mounting bolt and remove the 5th gear fork (Fig. 4-16). Simultaneously engage 2nd gear with the carrier of the 1st and 2nd gear fork and 5th gear with the synchronizer sliding sleeve and unscrew the bolts securing the ends of the primary and secondary shafts. Using a universal puller, press the synchronizer, synchronizer sliding sleeve, 5th gear and its needle bearing off the primary shaft (Fig. 4-17). Use a universal puller to remove the 5th gear from the secondary shaft.





Press the differential output shafts by screwing the bolt into one of the threaded holes in the flange with the bolt resting on a chisel placed between the flange and the differential housing (Fig. 4-19). Press the seals out of the differential housing. Unscrew the two bolts securing the reverse intermediate gear axle (Fig. 4-18). Remove the gear shift drive shaft and the locking cover, then the pins of the axles of the 1st and 2nd and 3rd and 4th gear shift forks.







Loosen the bolts securing the clutch housing to the gearbox housing. Do not loosen the four nuts securing the secondary shaft front bearing cover (Fig. 4-21). Remove the gearbox housing.



In the clutch housing, unscrew the four nuts securing the secondary shaft front bearing cover.

Remove the gear shift forks, primary shaft, secondary shaft, reverse intermediate gear shaft together with the drive gear and the differential from the clutch housing.