Volkswagen Golf Variant / Jetta. Manual - part 267

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  265  266  267  268   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 267

 

 

sion Housing Has Been Changed -arrow-

Area Below the Bearing Seat

Lower Washer

Through transmis‐

sion build date

4/9/06

not deeper.

no

From transmission

build date 10 04 6

slightly deeper.

yes

– Place a washer (85 mm outer circumference) -1- on the

grooved ball bearing -2-.

On Some Transmissions
Flattened Areas -A- on the Input Shaft Grooved Ball Bearing and

Bearing Mount -B-.
• Do not place any washers above and below the grooved ball

bearing.

• The flattened sides -A- on the grooved ball bearing and on the

bearing mount -B- must align in the transmission housing.

– Mark the flattened side with color.
– Transfer the markings to the upper area of the grooved ball

bearing and to the upper area of the transmission housing

bearing mount (⇒ next figure).

– Heat the transmission housing in the area near the bearing

seat for the grooved ball bearing/input shaft to approximately

100 °C (212 °F) for approximately 10 minutes using a Hot Air

Blower , for example, Hot Air Blower - VAG1416- .

11. Transmission, Disassembling and Assembling    

243

It is necessary to heat the transmission housing so that the

grooved ball bearing is not damaged when the housing is be‐

ing installed.

Align the marking on the grooved ball bearing -A- with the

marking on the transmission housing -B- and mount the trans‐

mission housing.

– For all transmissions heat the transmission housing with Hot

Air Blower - VAG1416- for example the Hot Air Blower -

VAG1416- in the grooved ball bearing/input shaft bearing set

area to 100 °C (212 °F) for approximately 10 minutes.

– Apply Sealing Paste - AMV 188 200 03- evenly onto the seal‐

ing surface of the clutch housing.

– Install the transmission housing and tighten the new bolts

-A-, -B and C- to the tightening specification.

If the steel bolts (out hex head) are the replacement part, pay

attention to the allocation:
A - Bolt with permanent washer
B - Bolt without washer
C - Bolt with permanent washer

– If a washer was mounted on the grooved ball bearing before

installation, then a washer -1- (outer diameter = 78.6 mm) must

be installed after installation -2-. Refer to 

⇒ page 242

 .

244

shaft.

– Install the selector shaft lock sleeve all the way onto the tool.

Refer to 

⇒ Fig. ““Lock Sleeve Differentiation”“ , page 266

 .

– Turn the transmission with opening for selector shaft in as‐

sembly stand upward.

Note

Use the Pry Lever - 80-200- to press against the spring force of

the securing bushing direction of -arrow- when installing so that

the gearshift shaft -1- does not touch the securing bushing -2-

when removing.

– Install the gearshift shaft -1- into the lower bearing -2- and into

the shift forks -3-.

Note

The cover is not shown in the illustration -item 2-

⇒ Item 2 (page 262)

 .

– Push the gearshift shaft -1- against the retaining sleeve -2- in

direction of -arrow- and guide is through the shift fork all the

way down using the shift finger -3-.

• The gearshift cover -4- must stand parallel to the bolting sur‐

face on the transmission housing.

• It must be possible to move the gearshift shaft easily (forward

and backward).

Note

If the gearshift cover is at an angle to the bolting surface, then the

gearshift shaft is not installed into the lower bearing.

11. Transmission, Disassembling and Assembling    

245

stalled when doing so.

– Install the Back-Up Lamp Switch - F4- -1-.

– Install the input shaft seal.

– Install clutch slave cylinder with release bearing and tighten

bolts -arrows- to tightening specification -item 4-

⇒ Item 4 (page 50)

 .

– Move the gearshift lever (selector lever) through all the gears.

– Drive the cap into transmission housing to all the way in the

Seal Installer - Crankshaft - T10042- .

246

 

 

 

 

 

 

 

Content   ..  265  266  267  268   ..