Assembly overview - cover for gearbox housing and 5th/6th gear — VW

Assembly overview - cover for gearbox housing and 5th/6th gear
Gearbox housing
Pull off together with 5th and 6th gears
Chapter
.
Repairing
Chapter
.
Gear wheel for 5th gear
Pull off individually
Chapter
Pull off together with gearbox housing
Chapter
Sleeve
Gear wheel for 6th gear
Pull off individually
Chapter
Pull off together with gearbox housing
Chapter
Cylindrical roller bearing inner race
For output shaft
Mark before removing
Do not interchange with inner race for cylindrical roller bearing of input shaft
Allocation
Fig.
Bolt
Self-locking.
For output shaft
Renew after each removal.
Allocation of bolts
Fig.
Clean residual locking fluid from threaded holes for securing bolts for gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear.
80 Nm +90°
Gearbox housing cover
With cylindrical roller bearings for input and output shafts
Repairing
Chapter
.
Bolt
For gearbox housing cover.
Qty. 5
18 Nm
Bolt
Self-locking.
For input shaft
Renew after each removal.
Allocation of bolts
Fig.
Clean residual locking fluid from threaded holes for 5th/6th gear synchro-hub securing bolts with a thread chaser. Otherwise the bolts may shear.
80 Nm +90°
Cylindrical roller bearing inner race
Not present, replaced by cylindrical roller bearing inner race with thrust washer
Thrust washer
Not present, replaced by cylindrical roller bearing inner race with thrust washer
Inner race for cylindrical roller bearing with thrust washer
For input shaft
Allocation of inner race for cylindrical roller bearing
Fig.
Sleeve
For 6th gear needle bearing.
Renew together with needle bearing
Allocation of components via
Electronic Parts Catalogue
Needle bearing
For 6th gear
Renew together with sleeve
Allocation of components via
Electronic Parts Catalogue
Synchromeshed gear for 6th gear
Allocation of components via
Electronic Parts Catalogue
Wave spring washer
In this case, install only locking piece springs without angled ends. (As shown in
Fig.
- item 1-)
For allocation see
Electronic Parts Catalogue
.
Synchro-ring for 6th gear
Locking collar with synchro-hub for 5th and 6th gears
Pull off individually
Chapter
Pull off together with gearbox housing
Chapter
Dismantling and assembling
Fig.
and
Fig.
adjusting
Fig.
.
Synchro-ring for 5th gear
Is damaged when removed from input shaft using
puller
T10309
Renew after removing using
puller
T10309
Wave spring washer
In this case, install only locking piece springs without angled ends. (As shown in
Fig.
- item 1-)
For allocation see
Electronic Parts Catalogue
.
Synchromeshed gear for 5th gear
Needle bearing
For 5th gear
Socket head bolt
For pivot pin to gearbox housing
25 Nm
Pivot pin
Selector fork for 5th/6th gear
Selector jaw for 5th/6th gear
Bolt
25 Nm
Allocation of securing bolts and cylindrical roller bearing inner races for input shaft
Dim.
“a”
mm
Dim.
“b”
mm
23.4
37
Additionally: inner race and thrust washer combined in one component
arrow
Allocation of securing bolts and cylindrical roller bearing inner races for output shaft
Dim.
“a”
mm
Dim.
“b”
mm
23.4
37