Input shaft, output shaft, differential and shift forks, removing and installing
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 following list pertains to Fig 1.
- Circlip
- Always replace
- Must seat firmly in groove
- 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-)
- Installation position, see TRANSMISSION HOUSING, SERVICING
- - Circlip for 4th gear
- Vehicles with 2.0 liter, 85 kW (115 hp) engine only
- 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
- 3rd gear
- Installation position, see AVAILABLE CIRCLIPS
- Adjust axial clearance, see AVAILABLE CIRCLIPS
- 2nd gear
- Needle bearing for 2nd gear
- Extracting inner race, see ASSEMBLING
- Pressing on inner race, see AVAILABLE CIRCLIPS
- 1st/2nd gear operating sleeve/synchronizer hub
- 1st gear
- Thrust washer
- Installation position, see ASSEMBLING
- Bolt
- Qty: 4
- Tightening torque: 25 N.m (18 ft lb) plus additional 1/4-turn (90°)
- Bearing cover
- With tapered roller bearing outer race and stop for reverse idler gear
- 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
- Differential
- Disassembling and assembling, see DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
- Gasket
- Always replace
- Tapered ring
- Spring with thrust washer
- Drive flange
- Installing, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING
- Dished washer
- Circlip
- Always replace
- Must seat firmly in groove
- Cover
- Always replace
- Clutch push rod
- Clutch housing
- Servicing, see CLUTCH HOUSING, SERVICING
- Modified version, see INSTALLING
- Reverse idler gear
- Shaft for reverse idler gear
- 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
- 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
- Shift fork for reverse gear
- Shift fork for 1st and 2nd gear
- Spring
- 5th gear selector bridge and tube
- Shift fork for 3rd and 4th gear
- Selector rod
- Spring