Volkswagen Workshop Service and Repair Manuals

Sequence for dismantling and assembling

• Clutch housing
• ◆ Servicing => page 34-102
• Hexagon bolt, 25 Nm
• Output shaft
• ◆ Dismantling and assembling => Page 35-18
• Input shaft
• ◆ Dismantling and assembling => Page 35-1
• Selector rod with selector fork for 3rd and 4th gear
• Selector rod with selector fork for 1st and 2nd gear
• Reverse gear shaft

• Selector rod for reverse gear
• Reverse gear
• ◆ Insert with shaft
• Reverse lever
• ◆ Insert with reverse gear selector rod
• Selector rod
• ◆ For 5th gear
• Bolt, 35 Nm
• ◆ For reverse gear shaft
• Reversing light switch, 20 Nm
• Bolt, 35 Nm
• ◆ For 5th gear and reverse gear selector rods
• Bolt, 35 Nm
• ◆ For reverse gear reverse lever

• 5th speed gear wheel
• Dished spring
• ◆ Concave side faces to 5th gear
• Bolt, 40 Nm
• ◆ Always renew
• Clip
• 5th gear selector fork
• ◆ With ball head bolt M8x1
• Gasket
• Gearbox housing cover
• Needle roller bearing
• ◆ For 5th gear
• 5th selector gear

• 5th gear synchro-ring
• ◆ Locking pieces are on synchro-ring
• Spring
• 5th gear synchro-hub
• Circlip
• ◆ Always renew
• ◆ Determining thickness => Page 34-98
• 5th gear locking collar
• Hexagon bolt, 10 Nm
• Hexagon socket head bolt,
  25 Nm
• Left-hand flanged shaft
• ◆ Do not interchange, left and right-hand flanged shafts differ
• Spring for flanged shaft

• Thrust washer
• Tapered ring
• Oil seal
• ◆ For left-hand flanged shaft
• ◆ Left and right-hand diameters differ.
• ◆ Renewing with gearbox installed => Page 39-1
• Plug
• Selector shaft

• Gearbox housing
• ◆ If replaced: =>Observe adjustment overview, Page 39-22
• ◆ Insert magnet in gearbox housing, held in place by housing joint surface
• ◆ Modification:
  From gearbox build date 23105, position of oil filler hole changed => Fig. 1 .
  Only install new gearbox housing in conjunction with oil collector. Installing oil collector => Fig. 2 .
  New gearbox housing can, in conjunction with oil collector, be installed to previous gearboxes. Filling quantity is then 2.7 ltr.
• ◆ Additional modification to gearboxes in conjunction with Diesel engine => Fig.3
• Differential
• ◆ Dismantling and assembling => page 39-8

• Selector console
• Spring
• Selector finger
• ◆ Modification:
  Vehicles with cable selector mechanism, spring in selector finger adapted => Fig.4
• Bush
• ◆ For selector console
• Bolt, 15 Nm
• Oil seal
• ◆ For right-hand flanged shaft
• ◆ Left and right-hand diameters differ
• ◆ Renewing with gearbox installed => Page 39-1
• Flanged shaft
• ◆ Do not interchange, left and right-hand flanged shafts differ

→ Fig.1     Position of oil filler hole changed from gearbox build date 23 10 5

→ Fig.2     Oil collector -A- installation position in gearbox housing, from gearbox date 23 10 5

• ‒ Insert oil collector into hole -arrow 1- and slot -arrow 2- simultaneously.

→ Fig.3     Gearbox housing for gearboxes in conjunction with Diesel engine

• ‒ If there is an eye/lug (arrow 2) present above the hole for the reversing light switch (arrow 1) then this must be sawn off at housing, if the gearbox is to be used in conjunction with a Diesel engine.

Vehicles with diesel engine, install starter before installing gearbox.

→ Fig.4     Modified selector finger for gearboxes used in conjunction with cable selector mechanism

Selector finger springs -A- and -B- have been modified for cable selector mechanism.

• ‒ This modified selector finger must not be installed in other gearboxes.

Note:

Allocate selector finger via parts catalogue.