Beetle L4-1.9L DSL Turbo (ALH) (1998)
Note:
The output shaft is disassembled as follows.
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Position separating device under 2nd gear (item 79) and press off as described in Fig, 5.
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Remove circlip (item 15).
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Position two-arm puller under bearing support (item 9) and pull off operating sleeve with 7st and 2nd gear synchronizer hub as described in Fig. 6.
When installing new gears or a new output shaft, consult technical data.
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Both tapered roller bearings must be replaced together as a set.
1
Nut
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25 Nm (18 ft. lbs.) + 90°
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4 nuts for bearing support
2
Clutch housing
3
Shim
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For output shaft
4
Small tapered roller bearing outer race
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Removing Fig 1
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Pressing in Fig 2
5
Small tapered roller bearing inner race
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Pulling off refer to Fig 3
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Pressing on refer to Fig 4
6
Output shaft
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Is paired with final drive gear; always replace together as a set
7
Large tapered roller bearing inner race
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Pulling off refer to Fig. 7
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Pressing on refer to Fig. 8
8
O-ring
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Qty. 4
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Place on bearing support bolts
9
Bearing support
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With large tapered roller bearing outer race and bolts
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Only change outer race together with large tapered roller bearing and bearing support
10
Thrust washer
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Shoulder on thrust washer faces tapered roller bearing
11
1st gear
12
Needle roller bearing
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For 1st gear