Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling sequence

Note:

When renewing

• ◆ Output flange (Item 9 ),
• ◆ Shaft bevel gear (Item 19 )

or

• ◆ Bevel gear with input shaft (item 37 )

Note differences between gearboxes for vehicles with 4-Cyl. engine and 6-Cyl. injection engine.

1)     Adjustment work is required if these components are replaced
          => Page 39-58

• Final drive housing1)
• ◆ Secure bevel box on assembly stand using gearbox support 3221 => Page 39-39 , drain oil first
• Oil drain plug, 20 Nm
• ◆ With magnet
• Sleeve for oil supply
• ◆ Pulling out => Page 39-47
• ◆ Pressing in
• O-ring
• ◆ Always renew
• O-ring
• ◆ Always renew
• O-ring
• ◆ Always renew
• Sleeve for oil supply
• ◆ Pulling out => Page 39-47
• ◆ Pressing in => Page 39-47

• Hexagon nut, 350 Nm
• ◆ Removing => Page 39-41
• ◆ Fitting => Page 39-53
• ◆ Always renew
• ◆ Coat with gearbox oil when installing
• Output flange1)
• ◆ Identifying the output flange => Page 39-53
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-3
• Shim S4
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-58
• ◆ Fit onto shaft bevel gear (item19 ) before inserting the small taper roller bearing inner race (item13 ) and before installing the seal (item 12 )
• ◆ Fit onto spacer ring (item11 ) on vehicles with 6-Cyl. engine gearboxes

• Spacer ring
• ◆ Only installed in gearboxes for vehicles with 6-Cyl. engine
• ◆ Installation position: Chamfer points towards shaft bevel gear (item19 )
• ◆ Fit onto shaft bevel gear (item19 ) before inserting the shim S4 and before installing the small taper roller bearing inner race (item13 ) and seal (item 12 )
• Oil seal
• ◆ Only replace with bevel box removed
• ◆ Pinion housing (item15 ) need not be removed
• ◆ Lever out with screwdriver
• ◆ Drive in flush with 40-21 and VW 204 b

• Small taper roller bearing for shaft bevel gear1)
• Outer race:
• ◆ Pressing out => Page 39-42
• ◆ Pressing in => Page 39-51
• Inner race:
• ◆ Place into outer race
• Bolt, 25 Nm
• Pinion housing1)
• ◆ Removing
• ◆ Installing => Page 39-52
• ◆ Do not cant when installing, tighten securing bolts in diagonal sequence and in stages
• O-ring
• ◆ Always renew
• ◆ Must lie in groove

• Shim S3
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-58
• ◆ The identification drilling (arrow) is located opposite to oil drain plug (item 2 )
• Large taper roller bearing for shaft bevel gear1)
• Inner race:
• ◆ Pulling off => Page 39-43
• ◆ Pressing on => Page 39-50
• Outer ring:
• ◆ Pulling out => Page 39-43
• ◆ Pressing in => Page 39-51
• Shaft bevel gear1)
• ◆ Is paired with bevel gear
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-3
• ◆ Adjusting => Page 39-63

• Circlip
• ◆ Always renew
• Roller sleeve
• ◆ Pulling out => Page 39-46
• ◆ Pressing in => Page 39-48
• Sealing cap
• ◆ Destroyed during removal
• ◆ Always renew
• Circlip
• ◆ Always renew
• Dished washer
• ◆ Cone points towards circlip
• Cone head bolt, 25 Nm
• ◆ To threaded piece on differential output shaft
• Drive flange
• ◆ Pull out with output shaft (item 38 )
• ◆ Pressing off => Page 39-54
• ◆ Pressing on => Page 39-54

• Spring for drive flange
• ◆ Length - 25 mm
• ◆ Do not interchange with gearbox spring
• Thrust washer
• ◆ Installation position:
  Shoulder towards spring, tongue to tapered ring
• Tapered ring
• ◆ With grooves to secure thrust washer
• ◆ Installation position:
  Chamfer towards bevel box
• Circlip
• ◆ Holds the tapered ring, thrust washer and spring in position when removing the output shaft/drive flange

• Oil seal
• ◆ Lever out with lever
• ◆ Drive in onto stop with drive sleeve 3158
  => Page 39-5
• ◆ Replacing with gearbox installed => Page 39-4
• Bolt, 25 Nm
• Cover plate1)
• ◆ Removing => Page 39-44
• ◆ Do not cant when installing, tighten securing bolts in diagonal sequence and in stages
• O-ring
• ◆ Always renew
• ◆ Must lie in groove

• Shim S1
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-58
• Large taper roller bearing to support bevel gear1)
• Inner race:
• ◆ Pulling off => Page 39-45
• ◆ Pressing on => Page 39-49
• Outer race:
• ◆ Pressing out => Page 39-44
• ◆ Pressing in => Page 39-50
• Bevel gear with input shaft1)
• ◆ Is paired to shaft bevel gear (item19 )
• ◆ Cannot be pressed off input shaft
• ◆ Adjusting => Page 39-73
• ◆ Allocate according to gearbox code letters using parts catalogue => Page 00-3

• Output shaft
• ◆ Pull out of bevel gear housing together with drive flange (item 26 )
• ◆ Pressing drive flange off and on => Page 39-54
• Small taper roller bearing to support bevel gear1)
• Inner race:
• ◆ Pressing off => Page 39-45
• ◆ Pressing on => Page 39-49
• Outer race:
• ◆ Pressing out => Page 39-46
• ◆ Pressing in => Page 39-48
• Shim S2
• ◆ Note thickness
• ◆ Adjustment overview
  => Page 39-58