Overview - Shafts, Differential, Gearshift Rods, AWD And Fwd With Front Axle Differential Lock

Fig 1: Exploded View Of Drive Axle, Output Shafts, Differential, Gearshift Rods, AWD

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. 1st through 4th Gear Output Shaft
   • Disassembling and Assembling. Refer to OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .
   • Installation position. Refer to Fig 2.
2. Shift Rod with 1st and 2nd Gear Shift Fork
   • Installation position. Refer to Fig 2.
3. Shift Rod with 3rd and 4th Gear Shift Fork
   • Installation position. Refer to Fig 2.
4. 5th, 6th and Reverse Gear Output Shaft
   • Disassembling and Assembling. Refer to 5TH/6TH AND REVERSE GEAR OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .
   • Installation position. Refer to Fig 2.
5. Shift Rod with 5th and 6th Gear Shift Fork
   • Installation position. Refer to Fig 2.
6. Reverse Gear Shift Fork
   • Installation position. Refer to Fig 2.
7. Input Shaft
   • Installation Position. Refer to Fig 2.
   • Disassembling and Assembling. Refer to OVERVIEW - INPUT SHAFT .
   • Replace grooved ball bearing on drive axle after removing. Refer to OVERVIEW - INPUT SHAFT .
8. Reverse Shaft
   • With a thrust washer
9. Thrust Washer
10. Bleeder
    • Connect with clutch slave cylinder
11. Clutch Housing
    • Servicing. Refer to OVERVIEW - CLUTCH HOUSING .
12. Input Shaft Seal
    • Replace after removing. Refer to INPUT SHAFT SEAL, REPLACING .
13. O-Ring
    • Install on the line connection
    • Coat with brake fluid before installing
14. Clutch Slave Cylinder with Release Bearing
15. Bolt
    • Replace after removing
    • Removing and installing. Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .
    • Quantity: 3
16. Bolt
    • Tightening Specification. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
17. Bolt
    • Replace after removing
    • Tightening Specification. Refer to OVERVIEW - DIFFERENTIAL, AWD AND FWD WITH FRONT AXLE DIFFERENTIAL LOCK .
    • Quantity: 4
18. AWD Bevel Box
    • Bevel Box Components. Refer to BEVEL BOX COMPONENTS
    • Removing and installing. Refer to BEVEL BOX .
19. Differential
    • Disassembling and Assembling. Refer to DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING, AWD, FWD WITH FRONT AXLE DIFFERENTIAL LOCK .

Shafts and Selector Rods in Transmission Installation Position 

Fig 2: Installation Location Of Shafts And Gearshift Rods In Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 -  Input Shaft

2 -  1st through 4th Gear Output Shaft

3 -  5th, 6th and Reverse Gear Output Shaft

4 -  Reverse Shaft

A -  3rd and 4th Gear Shift Rod

B -  1st and 2nd Gear Shift Rod

C -  5th and 6th Gear Shift Rod

D -  Reverse Gear Shift Fork

The reverse gear shift fork -D- is mounted on the 5th and 6th gear gearshift rod -C-.