Input shaft, output shafts (pinion shafts), differential, bevel gear transfer case and selector rods, removing and installing: Notes
WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: View Of Input Shaft, Output Shafts, Differential, Bevel Gear Transfer Case & Selector Rods Components
1 - Output shaft 1st to 4th gear
- Disassembling and assembling → Output shaft for 1st to 4th gear
- Installed position: Installed position of input shaft and output shafts (pinion shafts) in transmission up to transmission manufacture date 180503
2 - Selector rod with shift fork for 1st and 2nd gear
- Servicing, up to transmission manufacture date 180503 → Shift forks, servicing up to transmission manufacture date 180503
- Installed position, up to transmission manufacture date 180503, Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:
- Servicing, as of transmission manufacture date 190503 → Shift forks, servicing as of transmission manufacture date 190503
- Installed position, as of transmission manufacture date 190503: Installed position of shafts and selector rods in transmission, as of transmission manufacture date 190503:
3 - Selector rod with shift fork for 3rd and 4th gear
- Servicing, up to transmission manufacture date 180503 → Shift forks, servicing up to transmission manufacture date 180503
- Installed position, up to transmission manufacture date 180503, Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:
- Servicing, as of transmission manufacture date 190503 → Shift forks, servicing as of transmission manufacture date 190503
- Installed position, as of transmission manufacture date 190503: Installed position of shafts and selector rods in transmission, as of transmission manufacture date 190503:
4 - Output shaft 5th/6th and reverse gear
- Disassembling and assembling → Output shaft for 5th/6th and reverse gear
- Installed position: Installed position of input shaft and output shafts (pinion shafts) in transmission up to transmission manufacture date 180503
5 - Selector rod with shift fork for 5th and 6th gear
- Servicing, up to transmission manufacture date 180503 → Shift forks, servicing up to transmission manufacture date 180503
- Installed position, up to transmission manufacture date 180503, Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:
- Servicing, as of transmission manufacture date 190503 → Shift forks, servicing as of transmission manufacture date 190503
- Installed position, as of transmission manufacture date 190503: Installed position of shafts and selector rods in transmission, as of transmission manufacture date 190503:
6 - Shift fork for reverse gear
- Servicing, up to transmission manufacture date 180503 → Shift forks, servicing up to transmission manufacture date 180503
- Installed position, up to transmission manufacture date 180503, Installed position of complete shift mechanism in transmission, up to transmission manufacture date 180503:
- Servicing, as of transmission manufacture date 190503 → Shift forks, servicing as of transmission manufacture date 190503
- Installed position, as of transmission manufacture date 190503: Installed position of shafts and selector rods in transmission, as of transmission manufacture date 190503:
7 - Input shaft
- Disassembling and assembling, up to transmission manufacture date 180503 → Input shaft, disassembling and assembling up to transmission manufacture date 180503
- Disassembling and assembling, as of transmission manufacture date 190503 → Input shaft, disassembling and assembling as of transmission manufacture date 190503
8 - Reverse shaft
- With thrust washer
9 - Thrust washer
10 - Bleeder
11 - Bolt 0.12 Nm
- Self-locking
- Always replace
- Installed as of transmission manufacture date 06 04 0
12 - Locking plate
- Secures outer race/tapered roller bearing for input shaft
- Installed as of transmission manufacture date 06 04 0
13 - Clutch housing
- Servicing, up to transmission manufacture date 18053 → Clutch housing, servicing up to transmission manufacture date 180503
- Servicing, as of transmission manufacture date 19053 → Clutch housing, servicing as of transmission manufacture date 190503
14 - Seal for input shaft
15 - O-ring
- Install on line connection
- Coat with brake fluid before installing
16 - Slave cylinder with release bearing
17 - Hex bolt, 12 Nm
- Qty. 3
- Always replace
18 - Conical head bolt, 25 Nm
- Length of conical head bolt is matched to bevel gear transfer case
- Check part number of bevel gear transfer case
- When replacing bevel gear transfer case, allocate conical head bolt via Electronic Parts Catalog (ETKA)
19 - O-ring
- Always replace
20 - Bevel gear transfer case
- Removing and installing with transmission installed → Bevel gear transfer case, removing and installing
- Removing and installing with transmission removed → Sequence of disassembly and assembly for transmission up to manufacture date 180503
- Disassembling and assembling → Bevel gear transfer case, disassembling and assembling
21 - Bolt, 40 Nm plus 45 ° (1/8 turn)
- Always replace
22 - Washer
23 - O-ring
- Always replace
24 - O-ring
- Always replace
25 - Hex bolt, 12 Nm
- Always replace
26 - Speedometer Vehicle Speed Sensor (VSS)
NOTE:
- Discontinued as of transmission manufacture date 041102.
27 - O-ring
- Always replace
28 - Differential
- Disassembling and assembling → Differential, disassembling and assembling