Input shaft, output shaft, differential and shift forks, removing and installing

The following list pertains to Fig 1.

1. Circlip 
   • Always replace
   • Must seat firmly in groove
2. 4th gear 
   • Installation position, see TRANSMISSION HOUSING, SERVICING 

     For vehicles with 2.0 liter, 85 kW (115 hp) engine:

   • Internal diameter larger due to larger output shaft diameter
   • Supplemental circlip (-3-)
3. - Circlip for 4th gear 
   • Vehicles with 2.0 liter, 85 kW (115 hp) engine only
4. Circlip for 3rd gear 
   • Recheck for thickness, see AVAILABLE CIRCLIPS 
   • Vehicles with 2.0 liter, 85 kW (115 hp) engine: larger diameter, see AVAILABLE CIRCLIPS 
5. 3rd gear 
   • Installation position, see AVAILABLE CIRCLIPS 
   • Adjust axial clearance, see AVAILABLE CIRCLIPS 
6. 2nd gear 
7. Needle bearing for 2nd gear 
   • Extracting inner race, see ASSEMBLING 
   • Pressing on inner race, see AVAILABLE CIRCLIPS 
8. 1st/2nd gear operating sleeve/synchronizer hub 
9. 1st gear 
10. Thrust washer 
    • Installation position, see ASSEMBLING 
11. Bolt 
    • Qty: 4
    • Tightening torque: 25 N.m (18 ft lb) plus additional 1/4-turn (90°)
12. Bearing cover 
    • With tapered roller bearing outer race and stop for reverse idler gear
13. Output shaft assembly 
    • Disassembling and assembling, see OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING 
    • Modified output shaft on vehicles with 2.0 liter, 85 kW (115 hp) engine, see OUTPUT SHAFT APPLICATIONS 
14. Differential 
    • Disassembling and assembling, see DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING 
15. Gasket 
    • Always replace
16. Tapered ring 
17. Spring with thrust washer 
18. Drive flange 
    • Installing, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING 
19. Dished washer 
20. Circlip 
    • Always replace
    • Must seat firmly in groove
21. Cover 
    • Always replace
22. Clutch push rod 
23. Clutch housing 
    • Servicing, see CLUTCH HOUSING, SERVICING 
    • Modified version, see INSTALLING 
24. Reverse idler gear 
25. Shaft for reverse idler gear 
26. Input shaft 
    • Disassembling and assembling, see INPUT SHAFT, DISASSEMBLING AND ASSEMBLING 
    • Modified on vehicles with 2.0 liter, 85 kW (115 hp) engine, see INPUT SHAFT, DISASSEMBLING AND ASSEMBLING 
    • Remove deep groove ball bearing (arrow) before installing input shaft, see INPUT SHAFT, DISASSEMBLING AND ASSEMBLING 
    • Installing deep groove ball bearing in transmission housing, see TRANSMISSION HOUSING, SERVICING 
27. Adjustment shim 
    • No adjustment of input shaft is required. Install original adjustment shim after repairs
    • If no shim was installed, reassemble without shim
    • When bearing or clutch housing/transmission housing is replaced, shim is not required
28. Shift fork for reverse gear 
29. Shift fork for 1st and 2nd gear 
30. Spring 
31. 5th gear selector bridge and tube 
32. Shift fork for 3rd and 4th gear 
33. Selector rod 
34. Spring 
Fig 1: Removing And Installing Input Shaft, Output Shaft, Differential And Shift Forks
Courtesy of VOLKSWAGEN OF AMERICA, INC.