Disassembly and assembly sequence: Assembling
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.
The transmission is assembled in reverse order of disassembly. Pay particular attention to the following points:
Installation position of 1st gear thrust washer: shoulder -A- on inner diameter faces bearing cover -B-
Installation position of operating sleeve/synchronizer hub for 1st/2nd gear: groove on face -A- and outside teeth on operating sleeve -B- face 1st gear -C-
- Heat 1st/2nd gear operating sleeve/synchronizer hub to approx. 100 °C (212 °F), then place in position and drive firmly into place while turning synchronizer ring so that grooves align with keys.
- Install reverse idler gear, driving shaft in gently if necessary.
- Drive inner race of 2nd gear needle bearing on to stop.
- Install needle bearing, synchronizer ring, 2nd gear and 3rd gear.
Installation position on 3rd gear: shoulder (arrow) faces 2nd gear -A-
- Adjust axial clearance on 3rd gear as follows:
- Determine thickest circlip that can be inserted (available circlips, see AVAILABLE CIRCLIPS ), and install.