Gear Carrier: Reassembly
- Install pinion shaft needle bearing and circlip, ensure lettered side of bearing faces inside of carrier. On 5-speed, press mainshaft and shift rod into gear carrier.
- Install pinion shaft with shift rod. Shift into 4th gear. Shift into neutral. Install circlip below pinion head teeth. Install retaining ring and tighten to 162 ft. lbs. (225 N.m). Loosen retaining ring and retighten to specification.
- Peen retaining ring twice. Attach gear carrier to transmission housing and tighten bolts to 14 ft. lbs. (20 N.m). Install circlip and determine thickness of spacer for reverse gear by subtracting thickness "D" from thickness "C". See Fig 1
. Refer to REVERSE GEAR SPACER
for proper shim.
REVERSE GEAR SPACER
| Color |
Gap To Be Adjusted mm |
| White |
3.97-4.19 |
| Black |
4.10-4.39 |
| Green |
4.40-4.59 |
| Red |
4.60-4.90 |
Courtesy of VOLKSWAGEN UNITED STATES, INC.
- Install selected spacer, reverse gear, needle bearing and circlip. Install syncro, circlip and reverse gear with groove in the gear facing cover. Install needle bearing and washers.
- Install synchronizer for 1st-reverse shift fork with molybdemun coated side of synchro ring facing 1st gear. Coat threads of shift rod fork bolt with D6 locking compound and tighten to 14 ft. lbs. (20 N.m). Install 1st gear and needle bearing.
- Determine thickness of 1st gear shim needed. Measure depth "A" and dimension "B". See Fig 2
. Dimension "B" is calculated by measuring from gear carrier housing mounting surface to end of 1st gear teeth (dimension "C"), and then measuring 1st gear hub height to 1st gear teeth height (dimension "D"). Subtract dimension "C" from "D" to calculate dimension "B".
- Subtract dimension "B" from "A" to arrive at shim thickness needed. See 1ST GEAR SHIM CHART
for appropriate shim.
1ST GEAR SHIM CHART
| Measurement mm |
Shim Thickness mm |
| 0.95-1.14 |
.6 |
| 1.15-1.34 |
.8 |
| 1.35-1.54 |
1.0 |
| 1.55-1.74 |
1.2 |
| 1.75-1.94 |
1.4 |
| 1.95-2.14 |
1.6 |
| 2.15-2.47 |
1.8 |
- On all models, to complete reassembly reverse remainder of disassembly procedure. Ensure that interlock and intermediate pins are installed properly so that it is not possible to engage 2 gears at the same time.
Courtesy of VOLKSWAGEN UNITED STATES, INC.