Volkswagen Workshop Service and Repair Manuals

• Gearbox housing
• ◆ If replaced: Adjust input shaft and differential
• Needle roller bearing
• ◆ For output shaft
• ◆ Removing => Fig.1
• ◆ Installing and securing
  => Fig.2
• Oil filler plug, 25 Nm
• ◆ Without magnet
• Shim
• ◆ For input shaft
• ◆ Adjustment overview
  => Page 39-23

• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-10
• ◆ If replaced: Adjust input shaft
  => Page 35-13
• Outer race/taper roller bearing
• ◆ For output shaft
• ◆ Removing and installing
  => Page 35-30
• ◆ If replaced: Adjust output shaft
  => Page 35-44
• Shim
• ◆ For output shaft
• ◆ Adjustment overview
  => Page 39-23
• Outer race/taper roller bearing
• ◆ For input shaft
• ◆ Removing and installing
  => Page 35-6
• ◆ If replaced: Adjust input shaft
  => Page 35-13

• Needle bearing
• ◆ Removing and installing
  => Page 35-50
• Dowel sleeve
• ◆ Qty. 2
• Starter bush
• ◆ Pulling out => Fig.5
• ◆ Knocking in => Fig.6
• ◆ Can be replaced without removing gearbox
• Clutch housing
• ◆ If replaced: Adjustment overview
  => Page 39-23
• ◆ Differing gearbox to engine flanges: 4 cylinder engine

• O-ring
• ◆ Always renew
• ◆ Place on guide sleeve and apply multi-purpose grease
• Guide sleeve
• ◆ With oil seal
• ◆ Knocking-out oil seal => Fig.3
• ◆ Driving in oil seal => Fig.4
• ◆ Remove guide sleeve to change the oil seal
• Socket head bolt, 20 Nm
• ◆ Self-locking
• ◆ Always renew
• Speedometer drive, 30 Nm
• Oil drain plug, 25 Nm
• ◆ Without magnet

• Outer race/taper roller bearing
• ◆ For differential
• ◆ Driving out and in
  => Page 39-12
• ◆ If replaced: Adjust differential
  => Page 39-24
• Magnet
• ◆ Held in place by housing joint surface
• Outer race/taper roller bearing
• ◆ For differential
• ◆ Driving in and out
  => Page 39-9
• ◆ If replaced: Adjust differential
  => Page 39-24
• Shim
• ◆ For differential
• ◆ Adjustment overview
  => Page 39-23

• Sleeve
• ◆ For oil seal (Item 23 )
• ◆ Removing => Fig.7
• ◆ Installing => Fig.8
• Oil seal
• ◆ Renewing => Page 39-1

→ Fig.1     Driving out needle roller bearing

→ Fig.2     Knocking needle roller bearing in onto stop

• ‒ Secure needle roller bearing in gearbox housing at three points (120° offset) with a punch.

→ Fig.3     Driving oil seal out of guide sleeve.

→ Fig.4     Driving oil seal into guide sleeve onto stop.

→ Fig.5     Pulling out starter bush.

A - Internal extractor 12 ... 14.5 mm, e.g. Kukko 21/1

B - Counter support. e.g. Kukko 22/1

→ Fig.6     Driving in starter bush.

→ Fig.7     Lever out sleeve with screwdriver

→ Fig.8     Pulling sleeve in

• ‒ Pull sleeve in onto stop with thrust piece 3124 by turning on nut -B-.

Note:

When gearbox is dismantled press sleeve in with thrust piece 3124 onto stop.