Volkswagen Golf Variant / Jetta. Manual - part 178

 

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Volkswagen Golf Variant / Jetta. Manual - part 178

 

 

-B- for transmission housing to clutch housing in area of dif‐

ferential.

– Remove the bolts -A- that connect the clutch and transmission

housing.

Note

Do not remove the nuts -B- for the bearing mount on the output

shaft.

– Remove both flange shafts.
– Remove the flange shafts with the springs, thrust washers and

tapered rings.

Remove the Following Components Together with the Transmis‐

sion Housing:
♦ 5th Gear Synchronizer Hub
♦ 5th Gear Wheel

• Both Spacer Plate - T10408/3- must be attached to the 5th

gear wheel.

• The Spacer Plate must be located above the 2 ribs on the

housing, opposite each other -arrows-.

Note

There is a needle bearing under the 5th gear wheel.

Secure the straps so that the needle bearing does not touch

the 5th gear wheel when removing the transmission housing.

174

Special Tools:
♦ Puller - Transmission Gears - Thrust Piece - T10408/2-
♦ Spacer Plate - T10408/3-
♦ Kukko 18/1 puller (quantity: 2)
– Install the Puller - Transmission Gears - T10408- in the threa‐

ded holes in the transmission housing cover using the bolts

-A-.

A - M7 x 35 bolts with washers
Tightening specification 18 Nm
– Place the Puller - Transmission Gears - Thrust Piece -

T10408/2- on the shaft.

– Install the Puller - Kukko Puller - 60-150mm Width, 200mm

Length .

– Remove the 5th gear synchronizer hub, the 5th gear wheel

and the transmission housing by tightening the spindles -A-

(

1

/2 turn) alternating.

– Warm the 5th gear wheel slightly if necessary using the Hot

Air Blower VAG1416 - VAG1416- .

– Remove the shift forks -A- together with the gearshift rails.
– Remove the gearshift mechanism/reverse gear -B-.

7. Transmission, Disassembling and Assembling    

175

– Remove the reverse gear -A-, the input shaft -B- and the output

shaft -C-, one after the other, from the clutch housing.

– Remove the differential.

7.7.2

Assembling the Transmission

– Install the differential.
– Always replace the seals -arrows- for the bearing mount/out‐

put shaft.

Note

The illustration only shows 3 of the 4 seals.

– Insert output shaft -1- and output shaft -2- together.
– Tighten the output shaft bearing mount nuts to the specifica‐

tion -item 11- 

⇒ Item 11 (page 166)

 .

– Mount the reverse gear wheel -3- on the needle bearing inside

the clutch housing.

Shoulder -arrow- faces away from clutch housing.
– Make sure the reverse shaft -4- is complete

⇒ “3.1 Reverse Shaft, Disassembling and Assembling”,

page 246

 ; do not mount the support on the reverse shaft.

– Install the reverse shaft into the clutch housing.
– Clean all threaded holes in reverse shaft supports of locking

compound; cleaning can be done with a thread tap.

– Mount the reverse shaft support.

176

reverse gear shift fork -2-, the spring -3- and the sliding piece

-4-.

Reverse Gear Location

– Install the gearshift mechanism/reverse gear -A-.
– Install the shift forks -B- together with the gearshift rails.
Reverse gear supports -C- are located in front of selector rails.

– Install the M8 x 100 stud bolts -A- into reverse shaft support

so that the shaft is aligned after fitting the transmission hous‐

ing.

– Align the gearshift rails.

Note

The shift segments must be installed in the grooves on the locking

collars.

– Apply the Sealant - AMV 188 200 03- evenly onto the sealing

surface of the clutch housing.

– Install the transmission housing and tighten to the tightening

specification. Refer to -item 15- 

⇒ Item 15 (page 165)

 .

7. Transmission, Disassembling and Assembling    

177

 

 

 

 

 

 

 

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