Input shaft, disassembling and assembling: Notes
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.
NOTE:
When installing new gears, consult specifications, see CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, CAPACITIES .
Vehicles with 2.0 liter, 85 kW (115 hp) engine: the input shaft incorporates larger dimensions for the following:
- Splines for clutch disc
- Input shaft oil seal
- Front needle bearing
The following list pertains to Fig 1.
- Bolt
- M17
- Always replace
- 150 N.m (111 ft lb)
- Removing and installing, see TRANSMISSION HOUSING COVER AND 5TH GEAR, REMOVING AND INSTALLING
- Dished washer
- Operating sleeve/synchronizer hub for 5th gear
- Removing ASSEMBLING
- Installing, see Available circlips
- Installation position and assembly, see Installation position of 5th gear operating sleeve
- Stop ring
- Prevents locking keys from moving out of position
- Removing, see Removing stop ring
- Installing, see Installing stop ring
- Spring
- 5th gear operating sleeve
- Installation position, see Installation position of 5th gear operating sleeve
- Synchronizer hub
- Locking key
- Socket-head bolt
- M7 x 24
- 15 N.m (11 ft lb)
- Deep groove ball bearing
- Pressing off, see Pressing off deep groove ball bearing
- Pressed into transmission housing during installation of input shaft, see TRANSMISSION HOUSING, SERVICING
- Tension bracket
- Secures deep groove ball bearing
- 4th gear
- 4th gear synchronizer ring
- Check for wear, see Checking synchronizer ring
- Circlip
- Always replace
- Do not overstretch
- Must seat properly in groove
- Operating sleeve/synchronizer hub for 3rd/4th gear
- Pressing off, see Pressing off operating sleeve and synchronizer hub for 3rd and 4th gear
- Synchronizer hub identification, see Identification of 3rd/4th gear synchronizer hub
- Assembling, see Assembling 3rd/4th gear operating sleeve and synchronizer hub
- Installation position, see Installation position of 3rd/4th gear operating sleeve and synchronizer hub
- Pressing on, see Pressing on 3rd/4th gear operating sleeve and synchronizer hub
- Operating sleeve
- Synchronizer hub
- Locking key
- Spring
- Input shaft
- Different diameter for vehicles with 2.0 liter, 85 kW (115 hp) engine note, INPUT SHAFT, DISASSEMBLING AND ASSEMBLING
- Clutch housing
- Bores modified for larger input shaft on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Input shaft needle bearing
- Removing and installing, see CLUTCH HOUSING, SERVICING
- Seal for clutch pushrod
- Can be replaced without disassembling transmission (transmission removed)
- Removing, see Prying out oil seal for clutch pushrod
- Installation position, see Installation positions of oil seal and bushing
- Installing, see Driving in oil seal for clutch pushrod
- Bushing
- Installation position, see Installation positions of oil seal and bushing
- Extracting, see Extracting bushing for clutch pushrod
- Can be replaced without disassembling transmission (transmission removed)
- Installing, see Driving in clutch pushrod bushing to shoulder
- 3rd gear
- 3rd gear synchronizer ring
- Friction surface coated with molybdenum, check for wear, see Checking synchronizer ring
- Transmission housing
- Input shaft shim
- Input shaft adjustment not required
- Original adjustment shim should be reinstalled after repairs
- If no shim was installed, reassemble without shim
- When bearing or clutch housing/transmission housing is replaced, shim installation is not required.
- Removing and installing input shaft, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Thrust washer
- Installation position, see Installation position of 5th gear thrust washer
- After installing 5th gear synchronizer ring -31-, place 5th gear -30- on synchronizer hub -7-
- 5th gear
- 5th gear synchronizer ring
- Check for wear, see Checking synchronizer ring