Assembly overview - removing and installing input shaft, output shaft, differential, selector mechanism and selector forks — VW

Assembly overview - removing and installing input shaft, output shaft, differential, selector mechanism and selector forks
Differential
Dismantling and assembling
Chapter
Modification from gearbox date 06 05 2, bearing seat for tapered roller bearing enlarged on gearbox housing side
Chapter
.
Allocation
Electronic parts catalogue
Gearbox housing
Made of either aluminium or magnesium.
Repairing
Chapter
Modification from gearbox date 06 05 2, bearing seat for differential tapered roller bearing enlarged
Chapter
.
For aluminium gearbox housings only: shim S
1
for outer race of tapered roller bearing for differential discontinued from gearbox build date 04 12 6
Fig.
Bearing seat for tapered roller bearing outer race adapted in gearbox housing
Allocation
Electronic parts catalogue
Oil drain plug, torque setting
Fig.
Flange shaft with compression spring
Removing and installing
Chapter
Assembling
Chapter
Countersunk bolt
Removing and installing
Item
Bolt, 5 Nm + turn 90° further
Self-locking
Always renew
To secure bearing mounting with deep groove ball bearing for input and output shafts
Item
.
Hexagon flange nut, 23 Nm
For selector mechanism
Item
.
Self-locking
Always renew
O-ring
Always renew
Pivot pin
Bolt, 5 Nm + turn 90° further
Always renew
Selector shaft with selector shaft cover
(Selector unit)
Repairing
Chapter
Bolt, 5 Nm + turn 90° further
Always renew
Bolt, 6 Nm
Gearbox neutral position sender
G701
for vehicles with start/stop system
Reversing light switch
F4
, 20 Nm
Changed to captive seal shortly after introduction of gearbox.
Seal
Not fitted in all gearboxes
Selector mechanism
(Selector forks)
Dismantling and assembling
Chapter
Input shaft and output shaft with bearing mounting and deep groove ball bearing
If bearing mounting is separated from gearbox housing, then mounting must always be renewed.
Pressing bearing mounting off and on
Chapter
.
Dismantling and assembling input shaft
Chapter
Dismantling and assembling output shaft
Chapter
Reverse gear shaft
Reverse gear wheel
Bolt
For reverse gear shaft.
M6: 5 Nm then turn 90° further
M8: 25 Nm then turn 45° further
Always renew