Passat Sedan L4-1.9L DSL Turbo (AAZ) (1995)
^
For 3rd gear (3GR) and 4th gear (4GR)
^
Press off with 2nd gear and 3rd gear
27
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Sleeve for needle roller bearing
28
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Needle roller bearing for 4th gear (4GR)
29
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4th gear (4GR) synchronizer ring (synchro-ring)
30
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4th gear (4GR)
31
-
Thrust washer
32
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Needle roller bearing for output shaft
33
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Transmission housing
34
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Sleeve for output shaft needle roller bearing
35
-
5th gear
36
-
Belleville spring washer
37
-
Torx(r) socket-head bolt M10
^
Tightening torque: 8O Nm (59 ft lb)
Pressing Apart Output Shaft For Disassembly
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Position separate device under 2nd gear (19) and press off, which includes:
^
3rd gear (3GR)
^
4th gear (4GR) synchro-hub with operating sleeve
^
2nd gear
^
3rd gear (3GR)
^
4th gear (4GR) with transmission housing needle roller bearing sleeve
A = Separator, 22-115 mm e.g. Kukko 17/2
B = 17 mm hex-head bolt (M10 x 20)
NOTE: Support the separator tool so that the lst/2nd gear operating sleeve stays in position and is NOT pulled off.
COMPONENT DISASSEMBLY-IDENTIFICATION-INSPECTION PROCEDURES
NOTE: The numbers in (parentheses) below, refer to the component key for the exploded image above. The components which require
additional disassembly are listed below with a following procedure. The procedures are listed in the order the components are listed, and are not
intended to be a sequential disassembly/assembly procedure.
(4) Small tapered roller bearing outer race
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Bearing must be replaced as a set with large tapered roller bearing (7)
Removing Small Tapered Roller Bearing Outer Race
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A - Internal extractor: 37-46 mm e.g. US 1099 or Kukko 21/6
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B - Counter support e.g. US 1032 or Kukko 22/2