Passat Wagon L4-1.9L DSL Turbo (AHU) (1997)
Pressing In Tapered Roller Bearing Outer Race
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Insert with shim after adjusting input shaft
(11) Shim
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Determining thickness -- Ref Input Shaft See: Adjustments
(13) Sleeve for needle roller bearing
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Press off along with 4th gear (4GR) and tapered roller bearing inner race
InstallingSleeve For Needle Bearing
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Place thrust washer (9) in position first
(15) 5th gear
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Disassembly/Assembly -- Ref Manual Transmission, See: Service and Repair
(16) 5th gear synchronizer with cast locking lugs on synchro-ring
Checking 5th Gear Synchro-ring For Wear
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Before installing 5th gear, press synchro-ring onto cone of gear and measure gap a with feeler gauge
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Gap a = New 1.1 - 1.7 mm (0.O43-0.067 in)
Wear limit 0.5 mm (0.020 in)
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Position 5th gear together with needle roller bearing
Place 5th gear synchro-ring on gear
(17) Spring