Volkswagen Golf Variant / Jetta. Manual - part 192

 

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Volkswagen Golf Variant / Jetta. Manual - part 192

 

 

Note

Be careful not to damage the contact surface for the seal on the

input shaft.

– Fill the space between the sealing and dust lip -arrow- halfway

with Sealing Grease - G 052 128 A1- .

– Coat the outer circumference of the seal lightly with transmis‐

sion fluid.

– Install the seal all the way into the guide sleeve.
– Install the clutch release lever with the release bearing and

guide sleeve. Refer to

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

 .

Tightening Specifications
♦ Guide sleeve to the clutch housing. Refer to

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

 .

230

Output Shaft

⇒ “2.1 Output Shaft, Disassembling and Assembling”,

page 231
⇒ “2.2 Output Shaft, Adjusting”, page 242

2.1

Output Shaft, Disassembling and As‐

sembling

♦ Press Piece - Rod - VW407-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Rod - VW409-
♦ Press Piece - Rod - VW412-
♦ Press Piece - Multiple Use - VW512-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 4 - VAG1582/4-
♦ Puller - Taper Roller Bearing - Adapter 5 - VAG1582/5-
♦ Press Plate - VW402-
♦ Bearing Installer - Multiple Use - 32 - 111-
♦ Support Channels - VW457-
♦ Press Piece - Multiple Use - VW519-
♦ Press Piece - Multiple Use - VW429-
♦ Press Piece - 60mm - VW 415 A-
♦ Press Piece - Multiple Use - VW447H-
♦ Press Piece - Multiple Use - VW454-
♦ Press Piece - Multiple Use - VW455-
♦ Press Tube - 41-501-
♦ Puller - Kukko Internal - 36-46mm - Kukko 21/6-
♦ Puller - Kukko Quick Action Separating Tool - 22-115mm -

Kukko 17/2-

♦ Puller - Kukko Counterstay - Kukko 22/2-
♦ Inductive Heater - VAS6414-

Note

Disassemble the output shaft as follows: place the separating device under the 2nd gear wheel -item 21-

⇒ Item 21 (page 234)

 and remove it as described. Refer to

⇒ Fig. ““3rd/4th Gear Synchronizer Hub/Locking Collar, 2nd, 3rd and 4th Gear Wheel with Output Shaft

Needle Bearing Sleeve, Removing”“ , page 236

 . Remove the locking ring -item 17-

⇒ Item 17 (page 233)

 . Remove the locking collar and the 1st/2nd gear synchronizer hub as described in

⇒ Fig. ““Removing the Locking Collar with the Synchronizer Hub And Bearing Mount”“ , page 236

 .

Consult the Parts Catalog and the Technical data when installing new gear wheels or a new output shaft.

Refer to 

⇒ “2.3 Codes, Transmission Allocation and Capacities”, page 3

 .

Replace both tapered roller bearings together.

Wearing safety gloves, warm the bearing inner races, the gear wheels and the synchronizer hubs to ap‐

proximately 100 °C (212°F) using an Inductive Heater - VAS6414- before installing them.

2. Output Shaft    

231

❑ 25 Nm and 90° addition‐

al turn

❑ 4 nuts for the bearing

mount

❑ Always replace.

2 - Clutch Housing
3 - Shim

❑ For the output shaft
❑ Adjustment overview.

Refer to

⇒ “2 Adjustment Over‐

view”, page 262

 .

4 - Small Outer Race/Tapered

Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Remove the

Small Outer Race/Ta‐

pered Roller Bearing”“ ,

page 235

 .

❑ Installing. Refer to

⇒ Fig. ““Outer Race/

Small Tapered Roller

Bearing, Installing”“ ,

page 235

5 - Bearing Inner Race/Small

Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Bearing Inner

Race/Small Taper Roll‐

er Bearing”“ , page 236

❑ Installing. Refer to

⇒ Fig. ““Bearing Inner

Race/Small Tapered

Roller Bearing, Instal‐

ling”“ , page 236

6 - Output Shaft

❑ Adjusting. Refer to 

⇒ “2.2 Output Shaft, Adjusting”, page 242

 .

7 - Bearing Inner Race/Large Tapered Roller Bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Bearing Inner Race/Large Tapered Roller Bearing”“ , page 237

❑ Installing. Refer to

⇒ Fig. ““Installing the Bearing Inner Race/Large Tapered Roller Bearing”“ , page 237

8 - Seal

❑ Place the four seals on the bearing mount bolts.
❑ Always replace.

9 - Bearing Mount

❑ With the large outer race/tapered roller bearing and bolts
❑ Replace the outer race only together with the large tapered roller bearing and bearing mount

10 - Thrust Washer

❑ The collar on the thrust washer faces the tapered roller bearing

11 - 1st Gear Wheel
12 - Needle Bearing

❑ For 1st gear

232

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❑ (Inner race for 1st gear)
❑ Installation position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

237

 .

❑ Checking for wear. Refer to

⇒ Fig. ““Checking Inner Race for 1st Gear and 2nd Gear for Wear”“ , page 237

❑ Check for scoring

14 - 1st Gear Outer Race

❑ Installation position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

237

 .

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 238

❑ Replace if there are grooves or scoring

15 - 1st Gear Synchronizer Ring

❑ Installation position. Refer to

⇒ Fig. ““Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring”“ , page

237

 .

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 238

16 - Locking Collar with Synchronizer Hub for 1st and 2nd Gears

❑ After removing the locking ring -item 17- 

⇒ Item 17 (page 233)

 , remove with the bearing mount. Refer

to 

⇒ Fig. ““Removing the Locking Collar with the Synchronizer Hub And Bearing Mount”“ , page 236

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,

page 238

 .

❑ Assembling operating sleeve/synchronizer hub. Refer to

⇒ Fig. ““Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears”“ ,

page 238

 ,

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with Locking Pieces

that are Hollow on the Inside”“ , page 238

 and

⇒ Fig. ““Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears Together with Locking Pieces

that are not Hollow”“ , page 239

❑ Installation position. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears”“ , page 239

 .

❑ Installing. Refer to

⇒ Fig. ““Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.”“ , page 239

17 - Circlip
18 - 2nd Gear Synchronizer Ring

❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 238

❑ Insert it so that the holes engage into engagement pieces of locking collar -item 16-

⇒ Item 16 (page 233)

 .

19 - 2nd Gear Outer Race

❑ Insert into synchronizer ring -item 18- 

⇒ Item 18 (page 233)

 .

❑ Installation position. Refer to 

⇒ Fig. ““Installed Position of 2nd Gear Outer Race”“ , page 239

 .

❑ Replace if there are grooves or scoring

20 - Synchronizer ring

❑ (Inner race for 2nd gear)
❑ Checking for wear. Refer to

⇒ Fig. ““Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear”“ , page 238

❑ Check for scoring
❑ Installation position. Refer to

⇒ Fig. ““Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race)”“ , page 240

 .

2. Output Shaft    

233

 

 

 

 

 

 

 

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