volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Installing to engine and gearbox support > < Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3
Removing and installing input shaft, output shafts, differential and selector rods
   
Removing and installing input shaft, output shafts, differential and selector rods
1 - Output shaft for 1st through 4th gears
q   Dismantling and assembling → Chapter
q   Installation position → Fig.
2 - Selector rod with selector fork for 1st and 2nd gears
q   Repairing, through gearbox date 18 05 3 → Chapter
q   Installation position through gearbox date 18 05 3 → Fig.
q   Repairing, from gearbox date 19 05 3 onwards → Chapter
q   Installation position from gearbox date 19 05 3 → Fig.
3 - Selector rod with selector fork for 3rd and 4th gears
q   Repairing, through gearbox date 18 05 3 → Chapter
q   Installation position through gearbox date 18 05 3 → Fig.
q   Repairing, from gearbox date 19 05 3 onwards → Chapter
q   Installation position from gearbox date 19 05 3 → Fig.
4 - Output shaft for 5th, 6th and reverse gears
q   Dismantling and assembling → Chapter
q   Installation position → Fig.
5 - Selector rod with selector fork for 5th and 6th gears
q   Repairing, through gearbox date 18 05 3 → Chapter
q   Installation position through gearbox date 18 05 3 → Fig.
q   Repairing, from gearbox date 19 05 3 onwards → Chapter
q   Installation position from gearbox date 19 05 3 → Fig.
6 - Selector fork for reverse gear
q   Repairing, through gearbox date 18 05 3 → Chapter
q   Installation position through gearbox date 18 05 3 → Fig.
q   Repairing, from gearbox date 19 05 3 onwards → Chapter
q   Installation position from gearbox date 19 05 3 → Fig.
7 - Input shaft
q   Dismantling and assembling through gearbox date 18 05 3 → Chapter
q   Dismantling and assembling from gearbox date 19 05 3 → Chapter
8 - Reverse shaft
q   With thrust washer.
9 - Thrust washer
10 - Bleeder connection
q   Connect to slave cylinder → Item
11 - Bolt, 12 Nm
q   Self-locking
q   Always renew
q   Installed from gearbox build date 06 04 0
12 - Securing clip
q   Secures tapered roller bearing outer race for input shaft
q   Installed from gearbox build date 06 04 0
13 - Clutch housing
q   From gearbox date 06 04 0, with additional hole for bolt → Item and recess for locking plate → Item.
q   Repairing, through gearbox date 18 05 3 → Chapter
q   Repairing, from gearbox date 19 05 3 onwards → Chapter
14 - Input shaft seal
When gearbox is dismantled, oil seal can be removed with sleeve -30-21-.
q   Renewing → Item
15 - O-ring
q   Always renew
q   Pull onto line connection
q   Moisten with brake fluid before installing
16 - Slave cylinder with clutch release bearing
17 - Hexagon bolt, 12 Nm
q   Qty. 3
q   Always renew
18 - Countersunk bolt, 25 Nm
19 - Flange shaft with compression spring
q   Removing and installing → Chapter
q   Assembling → Chapter
20 - O-ring
q   Always renew
21 - Speedometer sender
  Note
t  From gearbox date 04 11 2, gradually discontinued.
t  The hole is then covered by a sealing cap secured with the original bolt → Item.
22 - Hexagon bolt, 12 Nm
q   Always renew
23 - Differential
q   Dismantling and assembling → Chapter

   
Installation position of input shaft and output shafts in gearboxes up to gearbox date 18 05 3
1 - Output shaft for 5th, 6th and reverse gears
2 - Input shaft
3 - Output shaft for 1st through 4th gears
4 - Differential
  N34-1036
Installation position of complete selector mechanism in gearbox, through gearbox date 18 05 3
1 - Selector fork for 3rd and 4th gears
2 - Selector fork for 1st and 2nd gears
3 - Selector fork for reverse gear
4 - Selector fork for 5th and 6th gears
5 - Selector shaft
The lower selector shaft mounting -arrow- is bolted to the cover plate on gearbox housing.
  N34-0993
Installation position of shafts and selector rods in gearbox, from gearbox date 19 05 3:
1 - Input shaft
2 - Output shaft for 1st through 4th gears
3 - Output shaft for 5th, 6th and reverse gears
4 - Reverse shaft
A - Selector rod for 3rd and 4th gears
B - Selector rod for 1st and 2nd gears
C - Selector rod for 5th and 6th gears
D - Selector fork for reverse gear
  N34-10022

Installing to engine and gearbox support > < Removing and installing gearbox housing and selector mechanism from gearbox date 19 05 3