Volkswagen Golf Variant / Jetta. Manual - part 304

 

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Volkswagen Golf Variant / Jetta. Manual - part 304

 

 

shaft.

Note

To remove right flange shaft, use Puller - Flanged Shaft - T10037-

to avoid damaging the bearing on flange shaft.

– Place a spacer (for example, Press Piece - Bushing - VW434- )

between the transmission support and the Stub Shaft coun‐

terhold Tool - Knurled Nut - T10371/1- .

– Align the Puller - Flanged Shaft - T10037- parallel to the flange

using the Spindle -A-.

– Install the right flange shaft.

Attach the Bearing Installer - Needle Bearing - T10047- , as

shown in the illustration, to the flange shaft.
• The markings “B” on both parts face each other.
• The depressions -arrows- must be under the bearing.
– Bolt the parts together all the way.

– Remove the locking ring -A- out of the needle bearing.

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Remove the old seal -A- from the groove -arrow-.

3. Overview - Seals, Flange Shaft Bearing and Output Flange Bearing inside the Bevel Box    

391

Installing

– Coat the new seal -A- with transmission fluid and insert it into

the groove -arrow- of the flange shaft.

Note

Make sure seal is not tilted.

– Attach the Bearing Installer - Needle Bearing - T10047- to the

flange shaft. Refer to 

⇒ page 391

 .

– So that the bearing contact surface on shaft is not damaged,

shaft must be rotated during the pressing procedure -arrow-.

– Secure the needle bearing with a new circlip.
– Carefully install the flange shaft while rotating it at the same

time.

– Install flange shaft with a screw and tighten to tightening spec‐

ification 

⇒ Item 13 (page 401)

 .

– Attach the right driveshaft heat shield to the bevel box

-arrows- and tighten it to the tightening specification. Refer to

⇒ “9.1.3 Tightening Specifications”, page 201

 .

– Check the gear oil in the bevel box. Refer to

⇒ “10 Axle Oil in Bevel Box, Checking or Adding”, page 218

 .

– Check transmission fluid level inside the manual transmission.

Refer to 

⇒ “8 Transmission Fluid, Checking”, page 192

 .

50 ; Noise Insulation .

– Install the right front wheel. Refer to ⇒  Suspension, Wheels,

cations .

392

Overview - Adjustment

Note

When performing repairs on the transmission, readjustment of the

output shaft for 1st to 4th gears, output shaft for 5th/6th gear and

reverse gears or differential is only required if components, which

have a direct influence on transmission adjustment, have been

replaced. Refer to Table to avoid any unnecessary adjusting.

 

 

To be adjusted:

 

 

Output shaft,

1st to 4th

gears. Refer

to

⇒ “2.3 Out‐

put Shaft 1st

through 4th

Gear, Ad‐

justing”,

page 340

 .

Output shaft,

5th/6th and

reverse

gears. Refer

to

⇒ “3.3 Out‐

put Shaft,

5th, 6th and

Reverse

Gears, Ad‐

justing”,

page 353

 .

Differential

Refer to

⇒ “5.3 Differ‐

ential, Ad‐

justing”,

page 405

 .

Replaced part:

Transmission Housing

x

x

x

 

Clutch Housing

x

x

x

 

1st through 4th Gear Output Shaft

x

 

 

 

5th, 6th and Reverse Gear Output

Shaft

 

x

 

 

Differential housing

 

x

 

Output shaft tapered roller bearing,

1st to 4th gears

x

 

 

 

Output shaft tapered roller bearing,

5th/6th and Reverse Gears

 

x

 

 

Differential tapered roller bearing

 

 

x

4. Overview - Adjustment    

393

Differential

⇒ “5.1 FWD Differential, Disassembling and Assembling”,

page 394
⇒ “5.2 Differential, AWD, Disassembling and Assembling”,

page 399
⇒ “5.3 Differential, Adjusting”, page 405

5.1

FWD Differential, Disassembling and

Assembling

Special tools and workshop equipment required
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW408A-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Multiple Use - 40-105-
♦ Press Piece - Multiple Use - 3005-
♦ Press Piece - Bushing - 3259-
♦ Press Piece - Reverse Gear Syncro - 3296-
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Puller - Taper Roller Bearing - VAG1582-
♦ Puller - Taper Roller Bearing - Adapter 6A - VAG1582/6A-
♦ Puller - Kukko Internal - 46-56mm - 21/7-
♦ Puller - Kukko Puller - 60-150mm Width, 200mm Length -

18/1-

♦ Puller - Kukko Quick Action Separating Tool - 12-75mm - 17/1-
♦ Puller - Kukko Counterstay - 22/2-
♦ Inductive Heater - VAS6414-

Note

Secure the transmission on the assembly stand. Refer to

⇒ “7 Transmission, Securing in Engine/Transmission Holder”, page 191

 .

Before installing, warm the inner race/tapered roller bearing to approximately 100 °C (212 °F) with Inductive

Heater - VAS6414- .

Adjust the differential when replacing the tapered roller bearing, differential housing, transmission housing

or clutch housing. Refer to 

⇒ “5.3 Differential, Adjusting”, page 405

 .

394

 

 

 

 

 

 

 

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