Output 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:
- Tapered roller bearings are only to be replaced as a set. After replacement, adjust the output shaft, see OUTPUT SHAFT, ADJUSTING .
- When installing new gears, consult Technical data, see CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, CAPACITIES .
- Removing and installing output shaft, see DISASSEMBLY AND ASSEMBLY SEQUENCE .
- Output shaft applications, see OUTPUT SHAFT APPLICATIONS .
The following have been modified for vehicles with the 2.0 liter, 85 kW (115 hp) engine:
- Increased hub spline diameter for 4th gear item.
- Additional groove and circlip for 4th gear, on 3rd gear side item.
The following list pertains to Fig 1.
- Transmission housing cover
- Needle bearing
- Removing and installing, see TRANSMISSION HOUSING COVER, SERVICING
- Attachment bolt
- Circlip for 5th gear
- Always replace
- Must seat firmly in groove
- Thrust washer
- Not installed on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Retainer plate for 5th gear
- Installed only on vehicles with 2.0 liter, 85 kW (115 hp) engine
- 5th gear
- Installing, see Available circlips
- Modified retainer on vehicles with 2.0 liter, 85 kW (115 hp) engine, see Retainer plate for 5th gear (for vehicles with 2.0 liter, 85 kW/115 hp engine only)
- Transmission housing
- Needle bearing
- Removing and installing, see TRANSMISSION HOUSING, SERVICING
- Circlip for 4th gear
- Always replace
- Must seat firmly in groove
- 4th gear
- Removing and installing, see DISASSEMBLY AND ASSEMBLY SEQUENCE
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional circlip on 3rd gear side item
- Larger internal diameter for modified output shaft
- Circlip for 4th gear
- Additional on vehicles with 2.0 liter, 85 kW (115 hp) engine
- Circlip for 3rd gear
- Always replace
- Must seat firmly in groove
- Recheck for thickness, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Increased diameter on vehicles with 2.0 liter, 85 kW (115 hp) engine, see AVAILABLE CIRCLIPS
- 3rd gear
- Installation position, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Adjusting axial clearance, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- 2nd gear
- Needle bearing for 2nd gear
- Extracting inner race, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- Pressing on inner race, see INPUT SHAFT, OUTPUT SHAFT, DIFFERENTIAL AND SHIFT FORKS, REMOVING AND INSTALLING
- 2nd gear synchronizer ring
- Friction surface coated with molybdenum
- Check for wear, see Checking synchronizer rings
CAUTION:- When replacing synchronizer rings, always refer to parts catalog microfiche for the correct parts application.
- Synchronizer rings that are being reused must not be interchanged.
- Operating sleeve/synchronizer hub for 1st/2nd gear
- Assembling, see Assembling operating sleeve and synchronizer hub for 1st and 2nd gear and Assembling synchronizer hub and operating sleeve
- Removing and installing, see Disassembly and assembly sequence
- Spring
- Operating sleeve
- Synchronizer hub
- Locking key
- 1st gear synchronizer ring
- Check for wear, see Checking synchronizer rings
- Identification, see MARKING OF 1ST GEAR SYNCHRONIZER RING WITH 110° tooth angle
- 1st gear
- Thrust washer
- Installation position, see ASSEMBLING
- Shim S3
- Adjustment summary, see ADJUSTMENT SUMMARY
- Outer race of small tapered roller bearing
- Extracting from clutch housing, see Extracting outer race of small tapered roller bearing from clutch housing
- Installing, see Driving outer race of small tapered roller bearing into clutch housing
- Inner race of small tapered roller bearing
- Pressing off, see Pressing off inner race of small tapered roller bearing
- Pressing on, see Pressing on inner races of small and large tapered roller bearings
- Clutch housing
- Output shaft
- Matched to final drive gear
- Vehicles with 2.0 liter, 85 kW (115 hp) engine: additional groove for 4th gear circlip, see OUTPUT SHAFT APPLICATIONS
- Adjust when replacing, see OUTPUT SHAFT, ADJUSTING
- Inner race of large tapered roller bearing
- Pressing off, see Pressing off inner race of large tapered roller bearing
- Pressing on, see Pressing on inner races of small and large tapered roller bearings
- Bearing cover
- With outer race of large tapered roller bearing and stop for reverse idler gear
- Bearing cover and outer race are single unit
- Do not press out outer race
- Hex-head bolt
- Tightening torque: 25 N.m (18 ft lb) plus additional 1/4 turn (90°)