A3 Mk2
Exploded view - servicing gearbox housing and clutch housing |
Special tools and workshop equipment required |
t | Drift -VW 295- |
t | Adapter -VW 295 A- |
t | Thrust plate -VW 447 H- |
t | Thrust pad -VW 512- |
t | Press tool -VW 454- |
t | Tube -2040- |
t | Puller -VW 228 B- (not used on this gearbox) |
t | Drift -VW 222 A- (not used on this gearbox) |
t | Assembly device -3066- (assembly device spindle) |
t | Thrust piece -3124- (for two-piece oil seal and sleeve) |
t | Multi-purpose tool -VW 771- (for one-piece oil seal and sleeve) |
t | Puller hook -VW 771/37- (for one-piece oil seal and sleeve) |
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1 - | Gearbox housing |
q | If renewed: Adjust input shaft and differential → Chapter |
2 - | Needle bearing |
q | For output shaft |
q | Removing → Fig. |
q | Installing and securing → Fig. |
3 - | Oil filler plug |
q | 35 Nm |
q | Gear oil level cannot be checked by removing oil filler plug |
q | If gearbox was dismantled, fill with gear oil before installing |
q | Capacity of manual gearbox (gearbox completely dismantled) |
t | 1.9 ltr. |
q | Capacity of manual gearbox (gearbox partially dismantled) → Chapter |
t | 1.7 ltr. |
4 - | Tapered roller bearing outer race |
q | For output shaft |
q | Removing and installing → Chapter |
q | If renewed: Adjust output shaft → Chapter |
5 - | Shim |
q | For output shaft |
q | Table of adjustments → Chapter |
6 - | Shim |
q | For input shaft |
q | Table of adjustments → Chapter |
7 - | Tapered roller bearing outer race |
q | For input shaft |
q | Removing and installing → Chapter |
q | If renewed: Adjust input shaft → Chapter |
8 - | Tapered roller bearing outer race |
q | For input shaft |
q | Removing and installing → Chapter |
q | If renewed: Adjust input shaft → Chapter |
9 - | Needle bearing |
q | Removing and installing → Chapter |
10 - | Dowel sleeve |
q | 2x |
11 - | Clutch housing |
q | If renewed: ⇒ table of adjustments → Chapter |
12 - | Guide sleeve |
q | With input shaft oil seal and vulcanised O-ring |
q | Driving out oil seal → Fig. |
q | Driving in oil seal → Fig. |
q | Remove guide sleeve in order to renew oil seal |
q | Renew guide sleeve if O-ring is damaged |
13 - | Socket head bolt |
q | 20 Nm |
14 - | Oil seal |
q | Renewing → Chapter „Renewing flange shaft oil seal (right-side) - two-piece oil seal and sleeve“ |
15 - | Sleeve |
q | For oil seal → Item |
q | Removing → Fig. |
q | Installing → Fig. |
16 - | One-piece oil seal and sleeve |
q | If oil seal is damaged, renew both sleeve and oil seal |
q | Removing → Fig. |
q | Installing → Fig. |
17 - | Oil drain plug |
q | 35 Nm |
q | Without magnet |
18 - | Tapered roller bearing outer race |
q | For differential |
q | Pressing out and pressing in → Chapter |
q | If renewed: adjust differential → Chapter |
19 - | Magnet |
q | Held in place by joint surface of housing |
20 - | Oil collector |
q | Installing oil collector in gearbox housing → Fig. |
21 - | Tapered roller bearing outer race |
q | For differential |
q | Pressing out and pressing in → Chapter |
q | If renewed: adjust differential |
→ Chapter |
22 - | Shim |
q | For differential |
q | Table of adjustments → Chapter |
23 - | Oil seal |
q | Renewing → Chapter „Renewing oil seal for flange shaft (left-side)“ |
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Note
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