Section 1 (5 SPD. Manual Transmission 020 (A3 Platform))
WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
- General, Technical Data
- Clutch
- Manual Transmission - Controls Housing
- Shift linkage, servicing
- Transmission, removing and installing
- Transmission, disassembling and assembling
- Transmission housing, servicing
- Clutch housing, servicing
- Transmission housing cover, servicing
- Manual Transmission - Gears Shafts
- Input shaft, disassembling and assembling
- Notes
- Prying out oil seal for clutch pushrod
- Installation positions of oil seal and bushing
- Driving in oil seal for clutch pushrod
- Extracting bushing for clutch pushrod
- Driving in clutch pushrod bushing to shoulder
- Pressing off deep groove ball bearing
- Pressing off operating sleeve and synchronizer hub for 3rd and 4th gear
- Checking synchronizer ring
- Identification of 3rd/4th gear synchronizer hub
- Assembling 3rd/4th gear operating sleeve and synchronizer hub
- Installation position of 3rd/4th gear operating sleeve and synchronizer hub
- Pressing on 3rd/4th gear operating sleeve and synchronizer hub
- Installation position of 5th gear operating sleeve
- Installation position of 5th gear thrust washer
- Removing stop ring
- Installing stop ring
- Output shaft, disassembling and assembling
- Notes
- Checking synchronizer rings
- Marking of 1st gear synchronizer ring with 110° tooth angle
- Assembling operating sleeve and synchronizer hub for 1st and 2nd gear
- Assembling synchronizer hub and operating sleeve
- Extracting outer race of small tapered roller bearing from clutch housing
- Driving outer race of small tapered roller bearing into clutch housing
- Pressing off inner race of small tapered roller bearing
- Pressing off inner race of large tapered roller bearing
- Pressing on inner races of small and large tapered roller bearings
- Retainer plate for 5th gear (for vehicles with 2.0 liter, 85 kW/115 hp engine only)
- Output shaft applications
- Output shaft, adjusting
- Input shaft, disassembling and assembling
- Final Drive, Differential
- Drive flange oil seals, removing and installing
- Differential, disassembling and assembling
- Notes
- Removing tapered roller bearing inner race
- Pressing on inner race of tapered roller bearing for differential housing
- Driving tapered roller bearing outer race out of transmission housing
- Driving tapered roller bearing outer race into transmission housing
- Driving tapered roller bearing outer race out of clutch housing
- Driving tapered roller bearing outer race into clutch housing
- Drilling out rivet heads
- Sawing off special rivets for removal of differential pinion gears
- Pressing off final drive gear
- Installing final drive gear
- Attaching final drive gear to differential housing
- Installing differential pinion gears
- Adjustment summary
- Differential, adjusting