volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Assembly overview - removing and installing clutch housing > < Overview - dismantling and assembling gearbox
Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th gears
   
Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th gears
1 - Gearbox housing
q   Repairing → Chapter.
2 - Gear wheel for 5th gear
q   Installation position → Fig.
q   Must be pressed off and pressed on in gearboxes for the 1.4l engine → Fig..
3 - Sleeve
4 - Gear wheel for 6th gear
q   Installation position → Fig.
5 - Cylindrical roller bearing inner race
q   For output shaft
q   Mark before removing
q   Do not interchange with inner race for cylindrical roller bearing of input shaft
6 - Bolt
q   M8: 30 Nm then turn 90° further
q   M10: 75 Nm then turn 45° further
q   For output shaft
q   Self-locking
q   Always renew
7 - Gearbox housing cover
q   With cylindrical roller bearings for input and output shafts
q   Repairing → Chapter.
8 - Bolt, 5 Nm + turn 90° further
q   Always renew
9 - Bolt
q   M8: 30 Nm then turn 90° further
q   M10: 75 Nm then turn 45° further
q   For input shaft
q   Self-locking
q   Always renew
10 - Cylindrical roller bearing inner race
q   For input shaft
q   Mark before removing
q   Do not interchange with inner race for cylindrical roller bearing of output shaft
11 - Thrust washer
12 - Inner race for cylindrical roller bearing with thrust washer
q   For input shaft
q   Installed in some gearboxes
q   Allocate according to → Electronic parts catalogue „ETKA“
13 - Synchromeshed gear for 6th gear
14 - Synchro-ring for 6th gear
15 - Needle bearing
q   One-piece
q   For 6th gear
q   Allocate according to → Electronic parts catalogue „ETKA“
q   Replace together with sleeve.
16 - Needle bearing
q   Two-part
q   For 6th gear
q   Installed in some gearboxes
q   Allocate according to → Electronic parts catalogue „ETKA“
q   Replace together with sleeve.
17 - Sleeve
q   For 6th gear needle bearing.
q   Renew together with needle bearing.
18 - Locking collar with synchro-hub for 5th and 6th gears
q   Dismantling and assembling → Chapter
19 - Selector fork for 5th and 6th gears
20 - Pivot pin
q   For 5th gear selector fork.
21 - Synchro-ring for 5th gear
q   Will be damaged during removal of input shaft
q   Always renew
22 - Synchromeshed gear for 5th gear
23 - Needle bearing
q   For 5th gear

   

Assembly overview - removing and installing clutch housing > < Overview - dismantling and assembling gearbox