Output Shaft, 5th, 6th And Reverse Gears Overview

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Inductive Heat Unit VAS 6414

NOTE:

Heat the bearing inner race/tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit VAS 6414. Wear protective gloves.

Replace both tapered roller bearings together.

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .

Fig 1: Exploded View Of Output Shaft For 5th, 6th And Reverse Gear Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Clutch Housing
Washer
- Always 0.65 mm thick.
Outer Race/Tapered Roller Bearing
- Removing, refer to Figure.
- Installing, refer to Figure.
Bearing Inner Race/Taper Roller Bearing
- Removing, refer to Figure.
- Installing, refer to Figure.
Output Shaft
- For 5th, 6th and reverse gears.
- Adjusting, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
Reverse Gear Synchronizer Hub
- Removing, refer to Figure.
- Installed position, refer to Figure.
- Installing, refer to Figure.
Locking Ring
Reverse Gear Locking Collar
- With the synchronizer ring.
Needle Bearing
- For reverse gear.
Reverse Gear
Sleeve
- Remove with the reverse gear, refer to Figure.
- Installed position: The wider sleeve collar faces the reverse gear.
- Installing, refer to Figure.
Locking Ring
Needle Bearing
- For 6th gear.
6th Gear
6th Gear Synchronizer Ring
- Checking for wear, refer to Figure.
Locking Collar with Synchronizer Hub for 5th and 6th Gears
- After removing the locking ring -item 17-, remove the 6th gear. Refer to Figure.
- Disassembling, refer to Figure.
- Assembling the locking collar/synchronizer hub, refer to Figure and to Figure.
- Installing, refer to Figure.
Locking Ring
Needle Bearing
- For 5th gear.
5th Gear Synchronizer Ring
- Checking for wear, refer to Figure.
5th Gear
Bearing Inner Race/Taper Roller Bearing
- Removing, refer to Figure.
- Installing, refer to Figure.
Locking Ring
- Select the correct one when replacing the tapered roller bearing -item 21- and the output shaft -item 5-. Refer to Figure.
Outer Race/Tapered Roller Bearing
- Removing, refer to Figure.
- Installing, refer to Figure.
Adjusting Shim
- To select the correct thickness, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
Transmission housing
Spring
- Installed position, refer to Figure.
Locking Collar
Synchronizer Hub
Locking Pieces
- Quantity: 3
- Installed position, refer to Figure.