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Home >> Volkswagen >> 2005 >> GTI Base, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 195 (Gears, Shafts - Manual Transmission 02Q (Sedan) (A5 Platform)) >> 35 Gears, Shafts >> Description And Operation >> Output Shaft, 1ST To 4TH Gears Overview

Output Shaft, 1ST To 4TH Gears Overview

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NOTE:

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING .

Replace both tapered roller bearings together.

Fig 1: Exploded View Of Output Shaft, 1st-4th Gear
GWWN35-0237Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Clutch Housing 
  2. Oil Deflector Washer 
  3. Concave Washer 
  4. Outer Race/Tapered Roller Bearing 
  5. Inner Race/Tapered Roller Bearing 
  6. Output Shaft 
  7. Needle Bearing 
    • For the 2nd gear.
  8. 2nd Gear 
  9. Synchronizer Ring, for 2nd Gear 
  10. 2nd Gear Outer Race 
  11. 2nd Gear Synchronizer Ring 
  12. Locking Collar with Synchronizer Hub for 1st and 2nd Gears 
  13. Lock Ring 
  14. 1st Gear Synchronizer Ring 
  15. 1st Gear Outer Race 
  16. Synchronizer Ring for 1st Gear 
  17. Needle Bearing 
    • For the 1st gear.
  18. 1st Gear 
  19. Thrust Washer 
    • For the 1st and 4th gears.
    • Quantity: 2
    • The tab on the thrust washer must fit into the hole in the output shaft.
  20. Washer 
    • Holds the thrust washers  Thrust Washer in place on the output shaft.
  21. Needle Bearing 
    • For the 4th gear.
  22. 4th Gear 
  23. 4th Gear Synchronizer Ring 
    • Made from brass or steel.
    • Checking for wear, refer to Figure.
  24. Locking Collar with Synchronizer Hub for 3rd and 4th Gears 
    • After removing the lock ring, remove the 4th gear, refer to "Lock Ring" in item  25 and see Figure.
    • Disassembling, refer to Figure.
    • Installed position: locking collar/synchronizer hub, refer to Figure.
    • Assembling the locking collar/synchronizer hub, refer to Figure and to Figure.
    • Installing, refer to Figure.
  25. Lock Ring 
  26. 3rd Gear Synchronizer Ring 
  27. 3rd Gear Outer Race 
  28. Synchronizer Ring for 3rd Gear 
  29. Needle Bearing 
    • For the 3rd gear.
  30. 3rd Gear 
  31. Inner Race/Tapered Roller Bearing 
  32. Lock Ring 
    • Select the correct one when replacing the tapered roller bearing and the output shaft. Refer to "Inner Race/Tapered Roller Bearing" in item 31, "Output Shaft" in item  6 and see Figure.
  33. Outer Race/Tapered Roller Bearing 
  34. Adjusting Shim 
  35. Transmission Housing 
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