Removing and installing cover for gearbox housing and 5th/6th gear — VW

Removing and installing cover for gearbox housing and 5th/6th gear
Gearbox housing
Pull off together with 5th/6th gear
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
Larger outer diameter from gearbox date 21 08 6
Allocation
Fig.
Bolt
For output shaft
Allocation of bolts
Fig.
To gearbox date 20 08 6: 40 Nm and 180° further
From gearbox date 21 08 6: 80 Nm and then turn 90° further
Self-locking
Always renew
Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th/6th gear and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear.
Gearbox housing cover
With cylindrical roller bearings for input and output shafts
Cylindrical roller bearings for input and output shafts from gearbox date 21 08 6 with larger outer diameter
Fig.
Repairing
Chapter
Bolts, 18 Nm
Qty. 5
For gearbox housing cover.
Bolt
For input shaft
Allocation of bolts
Fig.
To gearbox date 20 08 6: 40 Nm and 180° further
From gearbox date 21 08 6: 80 Nm and then turn 90° further
Self-locking
Always renew
Clean residual locking fluid from threaded holes for securing bolts for synchro-hub for 5th/6th gear and gear wheel for 6th gear with a thread chaser. Otherwise the bolts may shear.
Cylindrical roller bearing inner race
For input shaft
Mark before removing
Do not interchange with inner race for cylindrical roller bearing of output shaft
From gearbox date 21 08 6, combined with thrust washer in one component
Item
Allocation of inner race for cylindrical roller bearing
Fig.
Thrust washer
Through gearbox date 20 08 6
Inner race for cylindrical roller bearing with thrust washer
For input shaft
From gearbox date 21 08 6
Allocation of inner race for cylindrical roller bearing
Fig.
Sleeve
For 6th gear needle bearing
Renew together with needle bearing
Larger diameter from gearbox date 21 08 6
Allocation of components via
Electronic parts catalogue
Needle bearing
For 6th gear
Renew together with sleeve
Larger diameter from gearbox date 21 08 6
Allocation of components via
Electronic parts catalogue
Synchromeshed gear for 6th gear
Adapted to sleeve and needle bearing from gearbox date 21 08 6
Allocation of components via
Electronic parts catalogue
Wave spring washer
From gearbox date 26 05 8
In this case, install only locking piece springs without angled ends. (As shown in
Fig.
- item 1-)
Allocate according to
Electronic parts catalogue
.
Synchro-ring for 6th gear
Locking collar with synchro-hub for 5th and 6th gear
Pull off individually
Chapter
Pull off together with gearbox housing
Chapter
Dismantling and assembling
Fig.
and
Fig.
From gearbox date 12 06 6, locking collar modified
Fig.
Adjusting, through gearbox date 11 06 6
Fig.
Adjusting, from gearbox date 12 06 6
Fig.
Installation of springs with angled ends for locking pieces
Fig.
Synchro-ring for 5th gear
Will be damaged during removal of input shaft
Always renew
Wave spring washer
From gearbox date 26 05 8
In this case, install only locking piece springs without angled ends. (As shown in
Fig.
- item 1-)
Allocate according to
Electronic parts catalogue
.
Synchromeshed gear for 5th gear
Needle bearing
For 5th gear
Socket head bolt, 25 Nm
For pivot pin to gearbox housing
Pivot pin
5th/6th gear selector fork
Selector jaw for 5th/6th gear
Bolt, 25 Nm
Allocation of securing bolts and cylindrical roller bearing inner races for input shaft
Gearbox manufacture date
Dim.
“a”
mm
Dim.
“b”
mm
Through 20 08 6
21
31
From 21 08 6
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
Gearbox manufacture date
Dim.
“a”
mm
Dim.
“b”
mm
Through 20 08 6
21
31
From 21 08 6
23.4
37