volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling input shaft, output shaft, differential and selector forks > < Removing and installing cover for gearbox housing and 5th gear
Removing and installing gearbox housing and selector mechanism
   
Removing and installing gearbox housing and selector mechanism
1 - Oval-head countersunk screw M 7×23, 15 Nm
q   Qty. 4
q   Tensioning plate/deep groove ball bearing to gearbox housing
2 - Bolt, 20 Nm
q   For reverse gear shaft.
3 - Gearbox housing
q   Repairing → Chapter
q   From gearbox date 03 08 8, with additional threaded hole for reversing light switch.
q   Assembly of gearbox housing with additional threaded hole for gearboxes through date 02.08 8 → Fig..
4 - Sealing cover, 50 Nm
5 - O-ring
q   Renew if present.
6 - Compression spring
q   Presses selector shaft and gearbox selector lever into gate for 3rd and 4th gear
7 - Selector shaft
q   Dismantling and assembling → Chapter
8 - Hexagon bolt M 8 x 35, 25 Nm
q   Qty. 2
q   Screw in below locking bolt → Item.
9 - Reversing light switch and selector shaft locking bolt, 20 Nm
q   From gearbox date 03 08 8, reversing light switch and locking bolt are separate components → Fig..
q   Coat with sealant -AMV 188 200 03-.
10 - Seal
q   Renewing → Chapter
11 - Retaining ring
q   Holds tapered ring, thrust washer and spring in position when flange shaft is removed.
12 - Tapered ring
q   With grooves to engage in thrust washer
q   Installation position: taper towards differential cage
13 - Thrust washer
q   Installation position: shoulder faces spring, lugs face tapered ring
14 - Compression spring
15 - Flange shaft
q   Removing and installing → Chapter
16 - Hexagon socket head bolt, 25 Nm
17 - Hexagon bolt M 8 x 52, 25 Nm
q   Qty. 12
18 - Speedometer drive securing bolt, 5 Nm
19 - Retainer
20 - Speedometer drive
21 - O-ring
q   Always renew

   
From gearbox date 03 08 8, reversing light switch and selector shaft locking bolt are separate components.
t  Reversing light switch -1-
t  Locking bolt for selector shaft -2-
Specified torques
  N34-1173
Reversing light switch -1-25 Nm
Locking bolt -2-40 Nm

An additional threaded hole was added to the gearbox housing for the new reversing light switch -arrow-.
   
Assembly of gearbox housing with additional threaded hole for gearboxes through date 02 08 8
–  Seal additional threaded hole -arrow- with bolt M 12 x 1.5.
–  In place of new locking bolt for selector shaft, screw used locking bolt with reversing light switch -2- into gearbox housing.
Specified torques
  N34-1174
Reversing light switch -2-25 Nm
Hexagon head bolt M 12 x 1.5 -1-25 Nm

   

Dismantling and assembling input shaft, output shaft, differential and selector forks > < Removing and installing cover for gearbox housing and 5th gear