Tranny 1/2 shaft removal question

[Matteo]

Volks,

I have a 1990 Jetta NA diesel. Fifth gear blew (big surprise) and I want to pull the tranny and replace with a 1986 GWS I found with only 175k on it. I started to pull the half shafts, but it looks like there are torx bolts on there. If I had to guess, they look like 8mm. I tried a star 6 point but no go.
What is the size and type of bolt on there?
Is it torx?
Should I leave the current clutch on the engine and just swap out the tranny?
Is the mount for the 86 the same as the 90? Is there a throw out bearing? Any other speacial instructions to make this go smooth? I have the shop manual (Bently) but it does not mention bolt size or type.

Any help would be greatly appreciated.

Thanks,
Matt

[Jettagli16v]

NO TORX OR ALLEN!
(hopefully you have not tried yet!)

This is called a Triple Square bit.
should be available from any auto parts store in a pack of 4 that will have you covered (I bought a pack of 4 "OEM" brand from AutoZone, and have been using them for years....)
Also any tool shop should have them (sears, etc)

If the clutch is bad, replace.
(or if you are not a fan of transmission removal - I am not)
But if the PP is fine, a new Disc is the wear item.

The mounting bosses on the transmission case should be the same, but they did change the tranny mount (I believe) during the A2 run. you may have to transfer your mounts to the new box. (Or maybe that was just between MK1 and MK2...)

There is a throw out bearing, but it is easily serviceable with the trans in the car, not a big concern. It is accessable thru the green end cap behind your driver's side wheel.

Special instructions:
Only do this job on a lift with a transmission jack (or similar apparatus).

Good luck!
-Brad

[Jettagli16v]

Also,
though I should have mentioned this first,

the 5th can be replaced with the trans in the car.
If that is your only problem, just do that.

www.brokevw.com
He is the gospel on this work.

-Brad

[Rabbit TD]

Also,
though I should have mentioned this first,

the 5th can be replaced with the trans in the car.
If that is your only problem, just do that.

www.brokevw.com
He is the gospel on this work.

-Brad

I had the same thing happen last Summer about 70 mph.  It's peices also took the ring and pinnion gear along with it when it hopped out a little and banged and things started eating eachother inside, they all had a good meal :lol:  It wasn't a lack of oil situation, I didn't have it adjusted inside enough last time I had it apart.  But do yourself a favor and put a new input shaft seal on whatever transmission you get even if it looks like it isn't leaking.  It probably will and almost deffinately will if you ever switch to synthetic gear oil and when the trans does start dripping at the axels you won't have hurt the clutch and already have the hardest one to get to already in.  The Mr. Broke has them all as well as Autohause and they cost next to nothing and none are hard to change with the trans out.  I thought the old ones would be okay on that trans and lost that bet too when Royal Purple got on my just installed about a month before new clutch and leaked in the driveway and that stuff don't go away.

[Matteo]

Thanks for the help folks. I think I will replace the trans shaft seal. The original transmission is not worth fixing. It leaks from both sides where the 1/2 shafts connect. It pops out of 5th, but I am not inclined to put any time or effort into this pig as it has more than a few things wrong with it and I am told that it is the worst trans VW ever made and that the 86 is a great trans. I got the whole car for $500.00 and the trans looks dry and shifts nicely. The car only has 175k on it so I am confident it is solid. As an extra added bonus I get a complete engine and NICE interior along with a doors, hood, trunk. Basically identical to my 90. I'm thrilled. I'm debating on replacing the clutch. Are the pressure plates the same between 86 and 90?