Output shaft, disassembling and 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.
NOTE:
- The output shaft is to be disassembled as follows:
- When installing new gears or a new output shaft, refer to technical data, see Code letters, engine/transmission applications, ratios, capacities .
- Output shaft, removing/installing, see Input shaft, output shaft, differential and shift forks, removing and installing .
- Both tapered roller bearings must be replaced together, as a set.
The following list pertains to Fig 1 .
- Hex nut
- Tightening torque: 25 N.m (18 ft lb), plus additional 90° (1/4 -turn)
- For bearing support -9-
- Quantity: 4
- Clutch housing
- Shim
- Determining thickness, see OUTPUT SHAFT, ADJUSTING
- Small tapered roller bearing outer race
- Removing, see Pulling off small tapered roller bearing outer race
- Pressing in, see Pressing in small tapered roller bearing outer race
- Small tapered roller bearing inner race
- Pulling off, see Pulling off small tapered roller bearing inner race
- Pressing on, see Pressing on small tapered roller bearing inner race
- Output shaft
- Paired with final drive gear (differential ring gear); always replace as a set
- Adjusting, see OUTPUT SHAFT, ADJUSTING
- Large tapered roller bearing inner race
- Pulling off, see Pulling off large tapered roller bearing inner race
- Pressing on, see Pressing on large tapered roller bearing inner race
- Sealing rings
- Install on bolts for bearing support -9-
- Quantity: 4
- Bearing support
- With large tapered roller bearing outer race and bolts.
- Only replace outer race together with large tapered roller bearing and bearing support
- Thrust washer
- Shoulder on thrust washer faces tapered roller bearing
- 1st gear
- Needle roller bearing
- For 1st gear
- 1st gear synchronizer ring (synchro-ring)
- Checking for wear, see Checking synchro-ring for wear
- Identification, see Identification of 1st and 2nd gear synchro-rings
- 1st/2nd gear operating sleeve with synchronizer hub (synchro-hub)
- Removing:
- Remove circlip -15-
- Pull off operating sleeve/synchro-hub assembly using bearing support, see Pulling off operating sleeve with synchro-hub using bearing support
- Disassembling, see Disassembling and assembling 1st/2nd gear operating sleeve and synchro-hub
- Assembling operating sleeve and synchro-hub, see Disassembling and assembling 1st/2nd gear operating sleeve and synchro-hub and Assembling 1st/2nd gear operating sleeve and synchro-hub
- Installed position, see Installation position of 1st/2nd gear operating sleeve/synchro-hub
- Installing, see Pressing on 1st/2nd gear synchro-hub with operating sleeve
- Removing:
- Circlip
- 2nd gear synchronizer ring (synchro-ring)
- Identification, see Identification of 1st and 2nd gear synchro-rings
- Checking for wear, see Checking 2nd gear synchro-ring for wear
- Assemble so that recesses engage locking lugs on operating sleeve -14-
- 2nd gear synchronizer outer ring
- Engage in 2nd gear synchroring -16-
- Installation position, see Installation position for outer ring
- Replace if scored
- 2nd gear synchronizer inner ring
- Checking for wear, see Checking synchronizer inner ring for wear
- Check lugs for scoring
- Installed position, see Installation position for synchronizer inner ring -A-
- 2nd gear
- Installation position, see Installation position for 2nd gear
- Needle roller bearing
- For 2nd gear
- Thrust washer
- Sleeve
- For 3rd gear (3GR) needle roller bearing
- Pressing off with 2nd gear, see Pressing off 3rd gear (3GR)/4th gear (4GR) synchro-hub with operating sleeve, 2nd gear, 3rd gear (3GR) and 4th gear (4GR) with transmission housing needle roller bearing sleeve
- Pressing on, see Pressing on sleeve for 3rd gear (3GR) needle roller bearing
- Needle roller bearing
- For 3rd gear (3GR)
- 3rd gear (3GR)
- 3rd gear (3GR) synchronizer ring (synchro-ring)
- Checking for wear, see Checking synchro-ring for wear
- Operating sleeve with synchronizer hub (synchrohub)
- For 3rd gear (3GR)/4th gear (4GR)
- Press off with 2nd gear -19- and 3rd gear (3GR) -24-
- Disassembling, see Disassembling and assembling 3rd gear (3GR) and 4th gear (4GR) operating sleeve and synchro-hub
- Installation position for synchro-hub and operating sleeve, see Installation position of 3rd gear (3GR)/4th gear (4GR) operating sleeve/synchro-hub
- Assembling synchro-hub and operating sleeve, see Disassembling and assembling 3rd gear (3GR) and 4th gear (4GR) operating sleeve and synchro-hub and Assembling 3rd gear (3GR) and 4th gear (4GR) operating sleeve and synchro-hub
- Pressing on, see Pressing on 3rd gear (3GR)/4th gear (4GR) synchro-hub with operating sleeve
- Sleeve
- For needle roller bearing
- Press off with operating sleeve and 3rd gear (3GR)/4th gear (4GR) synchro-hub, see Pressing off 3rd gear (3GR)/4th gear (4GR) synchro-hub with operating sleeve, 2nd gear, 3rd gear (3GR) and 4th gear (4GR) with transmission housing needle roller bearing sleeve
- Pressing on, see Pressing on sleeve for 4th gear (4GR) needle roller bearing
- Needle roller bearing
- For 4th gear (4GR)
- 4th gear (4GR) synchronizer ring (synchro -ring)
- Checking for wear, see Checking synchro-ring for wear
- 4th gear (4GR)
- Thrust washer
- Needle roller bearing
- For output shaft
- Removing/installing, see Driving out needle roller bearing for output shaft
- Transmission housing
- Sleeve
- For output shaft needle roller bearing
- Pressing off, see Pressing off 3rd gear (3GR)/4th gear (4GR) synchro-hub with operating sleeve, 2nd gear, 3rd gear (3GR) and 4th gear (4GR) with transmission housing needle roller bearing sleeve
- Pressing on, see Pressing on sleeve for output shaft needle roller bearing
- 5th gear
- Removing/installing, see Transmission housing cover and 5th gear, removing/installing
- Belleville spring washer
- Installation position, see 5th gear synchro -with cast locking lugs
- Torx socket-head bolt
- M10
- Tightening torque: 80 N.m (59 ft lb)