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Home >> Volkswagen >> 2021 >> Jetta S, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Gears, Shafts (02Q, 0BB)) >> 35 Gears, Shafts >> Output Shaft >> Overview - Output Shaft >> Overview - Output Shaft, 1ST To 4TH Gears

Overview - Output Shaft, 1ST To 4TH Gears

WARNING: This page is about a different variant/trim than selected.
NOTE:

To install, warm the inner races/tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) using : VAS6414  . Wear protective gloves.

Install a collar bushing instead of thrust washers -item  ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Thrust Washer and retaining ring -item  ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Retaining Ring on transmissions with reinforcement measures (manual transmission 0FB). The output shaft components, 1st through 4th gear, 4th gear wheel and the needle bearing for the 4th gear wheel were adapted. Refer to Fig 2. Refer to the Parts Information.

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to OUTPUT SHAFT, ADJUSTING .

Replace both tapered roller bearings together.

Fig 1: Exploded View Of Output Shaft
GWWN35-10518Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Clutch Housing
  2. Oil Deflector Ring
  3. Dished Washer
  4. Outer Race/Tapered Roller Bearing
  5. Inner Race/Tapered Roller Bearing
  6. Output Shaft
  7. Needle Bearing
    • For 2nd gear
  8. 2nd Gear Assembly
  9. 2nd Gear Inner Race
    • Replace if there are wear grooves
    • Installation position. Refer to Figure.
  10. 2nd Gear Outer Race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installation position. Refer to Figure.
  11. 2nd Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear
    • Installation position. Refer to Figure.
  12. 1st and 2nd Gear Locking Collar with Synchronizer Hub
    • After removing the circlip, remove with the 2nd gear wheel. Refer to Figure.
    • Disassembling. Refer to Figure.
    • Locking Collar/Synchronizer Hub, Assembling. Refer to Figure and Figure.
    • Installation position. Refer to Figure.
    • Installing. Refer to Figure.
  13. Circlip
  14. 1st Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear
    • Installation position. Refer to Figure.
  15. 1st Gear Outer Race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installation position. Refer to Figure.
  16. 1st Gear Inner Race
    • Replace if there are wear grooves
    • Installation position. Refer to Figure.
  17. Needle Bearing
    • For 1st gear
  18. 1st Gear Assembly
    • Mount on the output shaft. Refer to Figure.
  19. Thrust Washer
    • For 1st and 4th gears
    • Insert the tab on the thrust washer into the output shaft hole
    • Not installed on transmissions with reinforcement measures
    • Quantity: 2
  20. Retaining Ring
    • Holds the thrust washers for the 1st and 4th gear in place on the output shaft
    • Not installed on transmissions with reinforcement measures
  21. Collar Bushing
    • For the 4th gear needle bearing
    • Only installed on transmissions with reinforcement measures. Refer to Fig 2
  22. Needle Bearing
    • For 4th gear
    • There are different versions. Refer to Fig 4
  23. 4th Gear Assembly
    • There are different versions. Refer to Fig 4
  24. 4th Gear Synchronizer Ring
    • Made of brass or steel
    • Checking for Wear. Refer to Figure.
  25. 3rd and 4th Gear Locking Collar with Synchronizer Hub
    • After removing the circlip, remove with the 4th gear wheel. Refer to Figure.
    • Disassembling. Refer to Figure.
    • Locking Collar/Synchronizer Hub, Assembling. Refer to Figure and Figure.
    • Locking Collar/Synchronizer Hub Installation Position. Refer to Figure.
    • Installing. Refer to Figure.
  26. Circlip
  27. 3rd Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear
    • Installation position. Refer to Figure.
  28. 3rd Gear Outer Race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installation position. Refer to Figure.
  29. 3rd Gear Inner Race
    • Replace if there are wear grooves
    • Installation position. Refer to Figure.
  30. Needle Bearing
    • For 3rd gear
  31. 3rd Gear Assembly
    • Mount on the output shaft. Refer to Figure.
  32. Inner Race/Tapered Roller Bearing
  33. Circlip
    • Determine again when replacing inner race/tapered roller bearing and output shaft. Refer to Figure
  34. Outer Race/Tapered Roller Bearing
  35. Shim
  36. Transmission Housing

Reinforcement Measures Near the 4th Gear Wheel 

Fig 2: Exploded View Of Reinforcement Measures On Manual Transmission
GWWA35-10496Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The following components are affected.

  1. Output Shaft

    Characteristics. Refer to Fig 3

  2. Collar Bushing

    Characteristics. Refer to Fig 4

  3. 4th Gear Needle Bearing

    Characteristics. Refer to Fig 4

  4. 4th Gear Assembly

    Characteristics. Refer to Fig 4

NOTE:

Never mix components for reinforced 4th gear transmissions and transmissions without 4th gear reinforcement. Refer to the Parts Information.

To remove and install modified components, follow instructions in repair information. Refer to 1ST TO 4TH GEAR OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING .

Differentiation of Output Shafts 

Fig 3: Differentiation of Output Shafts
GWWA35-10498Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Output Shaft -1- with Reinforcement Measures -1- without Reinforcement Measures
Dimension -a- 40.1 mm 42.0 mm
-Arrow A- Groove for collar bushing position -item  ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Collar Bushing -
-Arrow B- - Two opposite holes and circular groove for the thrust washer mounts -item  ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Thrust Washer

Differentiation of Needle Bearing and Gear Wheels for 4th Gear 

Fig 4: Variations of the Needle Bearing and Gear Wheels for 4th Gear
GWWA35-10497Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
4th Gear Assembly -1- with Reinforcement Measures -2- without Reinforcement Measures
Dimension -a- 52.0 mm 48.0 mm
4th Gear Wheel Needle Bearing -3- with Reinforcement Measures -4- without Reinforcement Measures
Dimension -b- 52.0 mm 48.0 mm
  • the needle bearing -3- is fitted on the collar bushing -5- on transmissions with reinforcement measures.
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