Removing and installing input shaft, output shafts, differential, bevel box and selector rods — VW

Removing and installing input shaft, output shafts, differential, bevel box and selector rods
1
Output shaft for 1st through 4th gears
Dismantling and assembling
Chapter
Installation position
Fig.
2
Selector rod with selector fork for 3rd and 4th gears
Repairing, through gearbox date 12 01 3
Chapter
Installation position through gearbox date 12 01 3
Fig.
Repairing, from gearbox date 13 01 3 onwards
Chapter
Installation position from gearbox date 13 01 3
Fig.
3
Selector rod with selector fork for 1st and 2nd gears
Repairing, through gearbox date 12 01 3
Chapter
Installation position through gearbox date 12 01 3
Fig.
Repairing, from gearbox date 13 01 3 onwards
Chapter
Installation position from gearbox date 13 01 3
Fig.
4
Output shaft for 5th, 6th and reverse gears
Dismantling and assembling
Chapter
Installation position
Fig.
5
Selector rod with selector fork for 5th and 6th gears
Repairing, through gearbox date 12 01 3
Chapter
Installation position through gearbox date 12 01 3
Fig.
Repairing, from gearbox date 13 01 3 onwards
Chapter
Installation position from gearbox date 13 01 3
Fig.
6
Selector fork for reverse gear
Repairing, through gearbox date 12 01 3
Chapter
Installation position through gearbox date 12 01 3
Fig.
Repairing, from gearbox date 13 01 3 onwards
Chapter
Installation position from gearbox date 13 01 3
Fig.
7
Input shaft
Dismantling and assembling through gearbox date 12 01 3
Chapter
Dismantling and assembling from gearbox date 13 01 3
Chapter
8
Reverse shaft
9
Thrust washer
10
Bleeder connection
Connect to slave cylinder
Item
11
Bolt, 12 Nm
Self-locking
Always renew
12
Securing clip
Secures tapered roller bearing outer race for input shaft
13
Clutch housing
Repairing, through gearbox date 12 01 3
Chapter
Repairing, from gearbox date 13 01 3 onwards
Chapter
14
Input shaft seal
Removing
Fig.
Installing
Fig.
15
O-ring
Always renew
Pull onto line connection
Moisten with brake fluid before installing
16
Slave cylinder with clutch release bearing
Removing and installing
Chapter
17
Hexagon bolt, 12 Nm
Qty. 3
Always renew
18
O-ring
Always renew
19
Bolt, 40 Nm
Always renew
20
Bevel box
Removing and installing with gearbox installed
Chapter
Removing and installing with gearbox removed
Chapter
Dismantling and assembling
Chapter
21
O-ring
Always renew
22
O-ring
Always renew
23
Countersunk bolt, 25 Nm
24
Right flange shaft
25
Compression spring for flange shaft
Installed behind flange shafts
26
Thrust washer
27
Bolt, 12 Nm
Always renew
For speedometer sender
From 01.03, for plugs
Allocation of components via
Electronic parts catalogue
28
Speedometer sender
From 01.03, discontinued for vehicles with ABS
Hole is then sealed with a plug and a seal
From gearbox date 17 04 6, plugs and seals discontinued
Allocation of components via
Electronic parts catalogue
29
O-ring
Always renew
30
Differential
Dismantling and assembling
Chapter
Installation position of output shafts in gearbox:
1 - Output shaft for 5th, 6th and reverse gears
2 - Input shaft
3 - Output shaft for 1st through 4th gears
4 - Differential
Installation position of complete selector mechanism in gearbox, through gearbox date 12 01 3
1 - Selector fork for 3rd and 4th gears
2 - Selector fork for 1st and 2nd gears
3 - Reverse gear selector fork
4 - Selector fork for 5th and 6th gears
5 - Selector shaft
The lower selector shaft mounting
arrow
is bolted to the cover plate on gearbox housing.
Installation position of shafts and selector rods in gearbox, from gearbox date 13 01 3:
1
Input shaft
2
Output shaft for 1st through 4th gears
3
Output shaft for 5th, 6th and reverse gears
4
Reverse shaft
A
Selector rod for 3rd and 4th gears
B
Selector rod for 1st and 2nd gears
C
Selector rod for 5th and 6th gears
D
Selector fork for reverse gear *)
In some gearboxes, mounting of reverse gear selector fork on selector rod for selector fork for 5th and 6th gears - C - . Distinguishing between reverse gear selector forks
Fig.
.