Volkswagen Golf Variant / Jetta. Manual - part 180

 

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Volkswagen Golf Variant / Jetta. Manual - part 180

 

 

and the shift jaw in direction of -arrow-. Tighten the bolt -1- to

25 Nm.

• Check measurement: it must not be possible to slide a 0.2 mm

feeler gauge between the locking collar and drive gear. Repeat

the adjusting procedure if necessary.

– Remove 5th gear. The locking collar must be in the neutral

position. The synchronizer ring must move freely.

– Move the gearshift lever (selector lever) through all the gears.
– Install the transmission housing cover. Refer to

⇒ “7.3 Cover for Transmission Housing and 5th Gear, Remov‐

ing and Installing”, page 162

 .

– Install the release bearing guide sleeve. Refer to

⇒ “2 Clutch Release Mechanism, Servicing”, page 45

 .

– Install the clutch release lever and release the bearing. Refer

to 

⇒ “2 Clutch Release Mechanism, Servicing”, page 45

 .

– Fill the transmission fluid. Refer to 

⇒ page 95

 .

182

Transmission Housing and Clutch

Housing, Servicing

Special tools and workshop equipment required
♦ Bearing/Bushing Installer - Multiple Use - VW 295-
♦ Bearing/Bushing Installer - Multiple Use - VW 295 A-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Multiple Use - VW512-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Front Control Arm - 2040-
♦ Puller - Starter Bushing - VW 228 B- (not needed with this

transmission)

♦ Pilot Drift - VW 222 A- (not needed with this transmission)
♦ Seal Installer - Driver Set - 3066- (spindle)
♦ Press Piece - Pivot Mount Bushing - 3124- (the seal and

sleeve are in two pieces)

♦ Slide Hammer Set - VW771- (the seal and sleeve are a single

piece)

♦ Slide Hammer Set - Hook - VW771/37- (the seal and sleeve

are a single piece)

♦ Seal Installer - One-Piece Seal - T10148- (the seal and sleeve

are a single piece)

8. Transmission Housing and Clutch Housing, Servicing    

183

❑ When replacing: adjust

the input shaft and

differential .Refer to

⇒ “2 Adjustment Over‐

view”, page 262

2 - Needle Bearing

❑ For the output shaft
❑ Removing. Refer to

⇒ Fig. ““Removing the

Needle Bearing”“ , page

186

 .

❑ Installing and securing.

Refer to

⇒ Fig. ““Installing the

Needle Bearing”“ , page

186

3 - Oil Filler Plug

❑ 35 Nm
❑ The gear oil level cannot

be checked by removing

the oil filler plug.

❑ If transmission was dis‐

assembled, it must be

filled before being instal‐

led again.

Capacity. Refer to

⇒ “2.3 Codes, Transmission

Allocation and Capacities”,

page 3

 .

4 - Outer Race/Tapered Roller

Bearing

❑ For the output shaft
❑ Removing and Instal‐

ling. Refer to

⇒ “2.1 Output Shaft, Disassembling and Assembling”, page 231

 .

❑ When replacing: adjust the output shaft. Refer to 

⇒ “2.2 Output Shaft, Adjusting”, page 242

 .

5 - Shim

❑ For the output shaft
❑ Adjustment overview. Refer to 

⇒ “2 Adjustment Overview”, page 262

 .

6 - Shim

❑ For the input shaft
❑ Adjustment overview. Refer to 

⇒ “2 Adjustment Overview”, page 262

 .

7 - Outer Race/Tapered Roller Bearing

❑ For the input shaft
❑ Removing and Installing. Refer to 

⇒ “1.1 Input Shaft, Disassembling and Assembling”, page 220

 .

❑ When replacing: adjust the input shaft. Refer to 

⇒ “1.2 Input Shaft, Adjusting”, page 226

8 - Outer Race/Tapered Roller Bearing

❑ For the input shaft
❑ Removing and Installing. Refer to 

⇒ “1.1 Input Shaft, Disassembling and Assembling”, page 220

 .

❑ When replacing: adjust the input shaft. Refer to 

⇒ “1.2 Input Shaft, Adjusting”, page 226

9 - Needle Sleeve

❑ Removing and Installing. Refer to 

⇒ “3.1 Reverse Shaft, Disassembling and Assembling”, page 246

 .

184

❑ Quantity: 2

11 - Clutch Housing

❑ When replacing: adjustment overview. Refer to 

⇒ “2 Adjustment Overview”, page 262

12 - Guide Sleeve

❑ With seal for the driveshaft and vulcanized O-ring
❑ Removing the seal. Refer to 

⇒ Fig. ““Removing the Seal from the Guide Sleeve”“ , page 186

❑ Installing the seal. Refer to 

⇒ Fig. ““Installing the Seal all the Way into the Guide Sleeve”“ , page 186

❑ Remove the guide sleeve to replace the seal
❑ Replace the guide sleeve and O-ring together if the O-ring is damaged.

13 - Cylinder Bolt

❑ 20 Nm

14 - Seal

❑ Replacing. Refer to

⇒ “1.4 Seal, Two-Piece Right Flange Shaft Seal and Sleeve, Replacing”, page 256

 .

15 - Sleeve

❑ For the seal -item 14- 

⇒ Item 14 (page 185)

❑ Removing. Refer to 

⇒ Fig. ““Prying out the Sleeve -arrow- ”“ , page 187

 .

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve”“ , page 187

 .

16 - Seal and Sleeve One-Piece

❑ If the seal is damaged, then replace both the seal and sleeve.
❑ Removing. Refer to 

⇒ Fig. ““Removing the Sleeve and Seal”“ , page 187

 .

❑ Installing. Refer to 

⇒ Fig. ““Installing the Sleeve and Seal”“ , page 187

 .

17 - Oil Drain Plug

❑ 35 Nm

18 - Outer Race/Tapered Roller Bearing

❑ For the differential
❑ Removing and installing. Refer to 

⇒ “3 Differential”, page 263

❑ When replacing: adjust the differential. Refer to 

⇒ “3.2 Differential, Adjusting”, page 269

19 - Magnet

❑ Held in place by housing joint surface

20 - Oil catch tray

❑ Install the oil catch tray into the transmission housing

⇒ Fig. ““Installing the Oil Catch Tray -A- into the Transmission”“ , page 188

21 - Outer Race/Tapered Roller Bearing

❑ For the differential
❑ Removing and installing. Refer to 

⇒ “3 Differential”, page 263

❑ When replacing: adjust the differential

⇒ “3.2 Differential, Adjusting”, page 269

22 - Shim

❑ For the differential
❑ Adjustment overview. Refer to 

⇒ “2 Adjustment Overview”, page 262

 .

23 - Seal

❑ Replacing. Refer to 

⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 255

 .

8. Transmission Housing and Clutch Housing, Servicing    

185

 

 

 

 

 

 

 

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