Polo Mk5
|
Note| t | When installing new gears or new output shaft, refer to → Electronic parts catalogue „ETKA“ and technical data. |
| t | Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil. |
| t | Do not interchange synchro-rings. When reusing always fit to the original gear. |
| 1 - | Clutch housing |
| q | Repairing → Chapter |
| 2 - | Cylindrical roller bearing |
| q | With retaining ring |
| q | Pulling out → Fig. |
| q | Pressing in → Fig. |
| q | Installation position: retaining ring in bearing faces output shaft |
| 3 - | Output shaft |
| q | If an inner race as bearing seat for cylindrical roller bearing (item → Item) is present, it cannot be removed from output shaft. |
| q | Check bearing seat or inner race for cylindrical roller bearing for scoring and damage. |
| q | If cylindrical roller bearing inner race or bearing seat is damaged or scored, renew output shaft and cylindrical roller bearing together. |
| 4 - | Gear wheel for 4th gear |
| q | Installation position: shoulder faces 3rd gear → Fig. |
| 5 - | Retaining ring |
| 6 - | Retaining ring |
| 7 - | Gear wheel for 3rd gear |
| q | Installation position: shoulder faces 4th gear → Fig. |
| 8 - | Retaining ring |
| 9 - | Synchromeshed gear for 2nd gear |
| 10 - | Needle bearing |
| q | For 2nd gear |
| 11 - | Bearing inner race for 2nd gear |
| q | Check for wear → Fig. |
| q | Installation position → Fig. |
| 12 - | Outer ring for 2nd gear |
| q | Set on inner ring → Item. |
| q | Renew if scored |
| q | Installation position → Fig. |
| 13 - | Synchro-ring for 2nd gear |
| q | Check for wear → Fig. |
| q | Installation position → Fig. |
| 14 - | Locking collar with synchro-hub for 1st and 2nd gears |
| q | After removing retaining ring → Item, press off with 2nd gear synchromeshed gear → Fig. |
| q | Dismantling → Fig. |
| q | Assembling locking collar and synchro-hub → Fig. and → Fig. |
| q | Installation position → Fig. |
| q | Pressing on → Fig. |
| 15 - | Retaining ring |
| q | Pressing out → Fig. |
| q | Installing → Fig. |
| 16 - | Synchro-ring for 1st gear |
| q | Check for wear → Fig. |
| q | Assemble so that notches engage in locking pieces of locking collar → Item |
| 17 - | Outer ring for 1st gear |
| q | Insert in synchro-ring → Item. Installation position → Fig.. |
| q | Renew if scored |
| 18 - | Inner ring for 1st gear |
| q | Check for wear → Fig. |
| q | Check lugs for scoring |
| q | Installation position → Fig. |
| 19 - | Needle bearing |
| q | For 1st gear |
| 20 - | Synchromeshed gear for 1st gear |
| q | Installation position → Fig. |
| 21 - | Bearing mounting with deep groove ball bearing |
| q | Renew deep groove ball bearing only together with bearing mounting |
| q | If bearing mounting is separated from gearbox housing, then mounting must always be renewed. |
| q | Press off without gear wheel for 5th gear → Fig. |
| q | Press off with gear wheel for 5th gear → Fig. |
| q | Pressing on → Anchor |
| 22 - | Gearbox housing |
| q | Repairing → Chapter |
| 23 - | Bolt |
| q | Removing and installing → Chapter |
| 24 - | Cylindrical roller bearing inner race |
| q | Mark before removing |
| q | Do not interchange with inner race for cylindrical roller bearing of input shaft |
| q | Removing and installing → Chapter |
| 25 - | Gear wheel for 6th gear |
| q | Installation position: → Fig.. |
| q | Removing and installing → Chapter |
| 26 - | Sleeve |
| q | Removing and installing → Chapter |
| 27 - | Gear wheel for 5th gear |
| q | Installation position: → Fig.. |
| q | Removing and installing → Chapter |
| 28 - | Spring |
| q | Installation position → Fig. |
| 29 - | Locking collar |
| 30 - | Synchro-hub |
| 31 - | Locking pieces (Qty. 3) |
