Transmission Housing Cover And 5TH Gear

Fig 1: Cover For Transmission Housing And 5th Gear, Removing And Attaching Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bolt
   • 18 Nm
   • For the cover to the transmission housing.
2. Transmission Housing Cover
   • From 11.10 with a magnet. Refer to Fig 2.
     NOTE:

     Note that fluid will leak out when the cover is removed with the transmission installed.

     Therefore the fluid must be drained and then filled again later. Refer to TRANSMISSION FLUID, CHECKING, DRAINING AND FILLING .

3. Gasket
4. Bolt
   • 80 Nm + 90° (1/4) additional turn.
   • Always replace.
   • Hold with the adapter on the concave washer bolt head in position
   • Clean the synchronizer hub and 5th gear drive gear threaded holes of locking fluid residue with a thread tap. Otherwise, there is the danger that the bolt could shear off.
5. Concave Washer
   • Installing, refer to Figure.
6. Bolt
   • 25 Nm
   • For the selector fork base to the transmission housing.
7. Base for Selector Fork
8. 5th Gear Selector Fork
   • Disassembly and assembling, refer to SELECTOR FORKS .
9. Spring
   • Offset version.
   • Installing, refer to Fig 3.
10. 5th Gear Locking Collar
    • Installed position, refer to Fig 4.
    • Adjusting, refer to Figure.
11. Locking Pieces
    • Quantity: 3
    • Installed position, refer to Fig 5.
12. Synchronizer Hub with Gear and 5th Gear Synchronizer Ring
    • Remove together with the transmission housing. Refer to TRANSMISSION .
    • Removing individually, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .
    • Disassembly and assembly, refer to Fig 4.
13. Needle Bearing
14. 5th Gear
    • Remove together with the transmission housing. Refer to TRANSMISSION .
    • Removing individually, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .
    • Installed position, refer to Figure.

Fig 2: Transmission Housing Cover with a Magnet

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The magnet -A- can be installed only to a cover with a recess -arrow-.

The magnet is held in place by the bolt for the 5th gear selector fork base when the cover is installed.

Fig 3: Identifying Offset Springs -A- For 5th Gear Synchronization

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 4: Assembling 5Th Gear Locking Collar/Synchronizer Hub

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Fig 5: Identifying Springs For Lock Pieces, Locking Collar With Recesses, Synchro-Hub & Locking Pieces With Thin Extension

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Fig 6: Assembling 5Th Gear Locking Collar/Synchronizer Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.