Transmission, disassembling/assembling: Assembling: Notes
WARNING: This page is about a different car, the 1999 Volkswagen GTI, 1998 Volkswagen GTI, 1997 Volkswagen GTI, 1996 Volkswagen GTI, and 1995 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.
- Install differential.
- Always install new sealing rings (-arrows-) on output shaft bearing support.NOTE: Illustration shows only three of the total of four sealing rings.
- Install input shaft, output shaft, and reverse shaft together.
- Tighten nuts for output shaft bearing support.
- Clean old thread-locking compound from threads on reverse idler shaft support using tap or equivalent thread cleaner.
- See INSTALLATION POSITION FOR 5TH GEAR , Fig 4 , -arrow-
- Install reverse idler shaft support.
- Install reverse gear selector mechanism.
- Check installed position of reverse gear.
- Install shift forks together with selector plates.
- Install locating stud -A- into reverse idler shaft support to maintain shaft alignment while installing transmission housing.
Courtesy of VOLKSWAGEN OF AMERICA, INC.
- Stud -A- = M8 x 100 mm
- Align selector plates.NOTE: The selector segments must be positioned in the grooves on the operating sleeves.
- Install transmission housing.
Install reverse shaft support bolts (arrow), as follows:
- Install bolt -a-, remove locating stud shown above, then install and hand-tighten bolt -b-. See Fig 4 .
- Tighten bolts in the following sequence:
- - Bolt -a-: 30 N.m (22 ft lb)
- - Bolt -b-: 30 N.m (22 ft lb)
- Align shift fork assembly with screwdriver and install shift fork pivot pin (-arrow-).
- Repeat until all four pivot pins are installed.
- Install selector shaft as follows:
- Place selector plates in neutral position.
- Position lug (arrow -1-) in recess in transmission housing.
- Position selector shaft so that finger (arrow -2-) can be inserted in selector plates.
- Install selector shaft cover.