Input 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:
- When installing new gears, refer to technical data, see Code letters, engine/transmission applications, ratios, capacities .
- Whenever the installed position of the input shaft tapered roller bearings is disturbed during parts replacement, the input shaft must be re-adjusted. See Adjustment overview .
The following list pertains to Fig 1 .
- Clutch housing
- Tapered roller bearing outer race
- Removing, see Pressing out tapered roller bearing outer race
- Pressing in, see Pressing in tapered roller bearing outer race
- Tapered roller bearing inner race
- Drive race off input shaft using drift
- Pressing on, see Pressing on tapered roller bearing inner race
- Input shaft
- Adjusting, see INPUT SHAFT, ADJUSTING
- 3rd gear (3GR)
- Shoulder faces toward 4th gear (4GR)
- Removing, see Pressing off 3rd gear (3GR)
- Pressing on, see Pressing on 3rd gear (3GR)
- Circlip
- Always replace
- 4th gear (4GR)
- Removing: Press off along with tapered roller bearing outer race and sleeve -13-, see Pressing off 4th gear (4GR) along with tapered roller bearing inner race and sleeve
- Pressing on, see Pressing on 4th gear (4GR)
- Shoulder faces toward 3rd gear (3GR)
- Tapered roller bearing inner race
- Removing: Press off along with 4th gear (4GR) and sleeve -13-, see Pressing off 4th gear (4GR) along with tapered roller bearing inner race and sleeve
- Pressing on, see Pressing on tapered roller bearing inner race
- Thrust washer
- Tapered roller bearing outer race
- Removing, see Pressing off tapered roller bearing outer race
- Pressing in, see Pressing in tapered roller bearing outer race
- Shim
- Determining thickness, see INPUT SHAFT, ADJUSTING
- Transmission housing
- Sleeve
- For needle roller bearing
- Press off along with 4th gear (4GR) and tapered roller bearing inner race, see Pressing off 4th gear (4GR) along with tapered roller bearing inner race and sleeve
- Pressing on, see Pressing on sleeve for needle roller bearing
- Installing: Place thrust washer -9- in position first
- Needle roller bearing
- 5th gear
- Pull off together with 5th gear synchro-hub, see 5th gear synchro -with cast locking lugs
- 5th gear synchronizer
- With cast locking lugs on synchro-ring, see 5th gear synchro -with cast locking lugs
- Checking for wear, see 5th gear synchro-ring, checking for wear
- Spring
- Installation position, see Assembling 5th gear operating sleeve and synchro-hub
- Lock pieces
- Quantity: 3
- Installation position, see 5th gear synchronizer
- - 5th gear synchronizer hub (synchro-hub)
- Removing/installing, see Assembling
- 5th gear operating sleeve
- Removing/installing, see 5th gear synchro-ring, installation position
- Belleville spring washer
- Installation position, see 5th gear synchro -with cast locking lugs
- Torx(R) socket-head bolt
- M10
- Tightening torque: 80 N.m (59 ft lb)