LEMON Manuals: Even more car manuals for everyone
Home >> Volkswagen >> 2018 >> Beetle S, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different car >> Section 113 (Gears, Shafts - Manual Transmission 0A4 (Convertible)) >> 35 Gears, Shafts >> Description And Operation >> Output Shaft Overview

Output Shaft Overview

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

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

Refer to the Parts Information and to CODES LETTERS, ALLOCATION AND CAPACITIES , when installing new gears or a new input shaft.

Replace both tapered roller bearings together.

Heat the toothed gear and synchronizer hub to approximately 100 °C using the Hot Air BlowerV.A.G. 1416. Wear safety gloves.

Fig 1: Identifying Output Shaft, Disassembling And Assembling Overview
GWWN35-0326Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Nut
  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.
    • Always replace after removing.
  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 locking ring -item 17-, remove with the bearing support, refer to Figure.
    • Disassembling, 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. Locking Ring
  18. 2nd Gear Synchronizer Ring
    • Checking for wear, refer to Figure.
    • Insert it so that the holes engage into engagement pieces of locking collar -item 16-.
  19. 2nd Gear Outer Race
    • Insert in the 2nd gear 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
    • Remove with the 2nd gear, refer to Figure.
    • Installing, refer to Figure.
  25. Needle Bearing
    • For 3rd gear -26-.
  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 2nd gear -item 21- and 3rd gear -item 26-, refer to Figure.
    • Disassembling, refer to Figure.
    • Assembling the 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 4th gear needle bearing -30-.
    • 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 -32-.
  31. 4th Gear Synchronizer Ring
    • Checking for wear, refer to Figure.
  32. 4th Gear
  33. Thrust Washer
  34. Needle Bearing
  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: Identifying Installed Position Of Plate Springs For 5th Gear Synchronizer Hub And Drive Gear Securing Bolts
GWWV34-2658Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Fig 3: Identifying Installed Position Of Plate Springs For 5th Gear Synchronizer Hub And Drive Gear Securing Bolts
GWWV34-2658Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
scientia non olet · About LEMON Manuals