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Home >> Volkswagen >> 2008 >> R32 >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (Gears, Shafts - 5-Speed Manual Transmission 0A4 (As Of 06.2011)) >> 35 Gears, Shafts >> Description And Operation >> Output Shaft Overview

Output Shaft Overview

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NOTE:

Disassemble the output shaft as follows: place the separating device under the 2nd gear -item 21- and remove it as described in Figure. Remove the lock ring -item 17-, locking collar and 1st/2nd gear synchronizer hub as described in Figure.

Refer to CODE LETTERS, TRANSMISSION ALLOCATION AND CAPACITIES when installing new gears or a new output shaft.

Replace both tapered roller bearings together.

Fig 1: Output Shaft, Disassembling And Assembling Overview
GWWN35-0326Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Nut
    • 25 Nm + 90° (1/4) additional turn.
    • Always replace.
    • 4 nuts for the bearing support.
  2. Clutch Housing
  3. Adjusting Shim
  4. Small Outer Race/Tapered Roller Bearing
  5. Bearing Inner Race/Small Tapered Roller Bearing
  6. Output Shaft
  7. Bearing Inner Race/Large Tapered Roller Bearing
  8. Seal
    • Place the four seals on the bearing support studs.
  9. Bearing Support
    • With the large outer race/tapered roller bearing and bolts.
    • Replace the outer race only together with the large tapered roller bearing and bearing support.
  10. Thrust Washer
    • The collar on the thrust washer faces the tapered roller bearing.
  11. 1st Gear
  12. Needle Bearing
    • For 1st gear.
  13. Synchronizer Ring
    • (Inner race for 1st gear)
    • Installed position, refer to Figure.
    • Checking for wear, refer to Figure.
    • Check for scoring.
  14. 1st Gear Outer Race
    • Installed position, refer to Figure.
    • Checking for wear, refer to Figure.
    • Replace if there are grooves or scoring.
  15. 1st Gear Synchronizer Ring
    • Installed position, refer to Figure.
    • Checking for wear, refer to Figure.
  16. Locking Collar with Synchronizer Hub for 1st and 2nd Gears
    • After removing the lock ring -item 17-, remove with the bearing support. Refer to Figure.
    • Disassembly, refer to Figure.
    • Assembling the operating sleeve/synchronizer hub. Refer to Figure, Figure and Figure.
    • Installed position, refer to Figure.
    • Installing, refer to Figure.
  17. Lock Ring
  18. 2nd Gear Synchronizer Ring
    • Checking for wear, refer to Figure.
    • Insert it so that the holes engage into the engagement pieces of the locking collar -item 16-.
  19. 2nd Gear Outer Race
    • Insert into the synchronizer ring -item 18-.
    • Installed position, refer to Figure.
    • Replace if there are grooves or scoring.
  20. Synchronizer Ring
    • (Inner race for 2nd gear)
    • Checking for wear, refer to Figure.
    • Check for scoring.
    • Installed position, refer to Figure.
  21. 2nd Gear
    • Installed position, refer to Figure.
  22. Needle Bearing
    • For 2nd gear.
  23. Thrust Washer
  24. Sleeve for the 3rd Gear Needle Bearing
    • Removing with the 2nd gear, refer to Figure.
    • Installing, refer to Figure.
  25. Needle Bearing
    • For 3rd gear.
  26. 3rd Gear
  27. 3rd Gear Synchronizer Ring
    • Checking for wear, refer to Figure.
  28. Locking Collar with Synchronizer Hub for 3rd and 4th Gears
    • Remove with the 2nd gear -item 21- and 3rd gear -item 26-. Refer to Figure.
    • Disassembly, refer to Figure.
    • Assembling operating sleeve/synchronizer hub. Refer to Figure, Figure and Figure.
    • Installed position: locking collar/synchronizer hub, refer to Figure.
    • Installing, refer to Figure.
  29. Sleeve
    • For the needle bearing.
    • Removing with the locking collar and the 3rd/4th gear synchronizer hub -item 28-. Refer to Figure.
    • Installing, refer to Figure.
  30. Needle Bearing
    • For 4th gear.
  31. 4th Gear Synchronizer Ring
    • Checking for wear, refer to Figure.
  32. 4th Gear
  33. Thrust Washer
  34. Needle Bearing
    • For the output shaft.
    • Removing and installing, refer to Fig 2.
  35. Transmission Housing
  36. Sleeve
    • For the needle bearing/output shaft.
    • Removing, refer to Figure.
    • Installing, refer to Figure.
  37. 5th Gear
  38. Plate Spring
    • Installed position, refer to Figure.
  39. Bolt
Fig 2: Driving Out Needle Bearing
GWWV35-1149Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Fig 3: Installed Position Of Plate Springs For 5Th Gear Synchronizer Hub And Drive Gear Securing Bolts
GWWV34-2658Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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