Input and output shafts 020, 5-speed (VW Golf 2)

Input shaft

1. If the clutch pusher has a gap in the input shaft bushing, it is necessary to remove the bushing from the end of the input shaft together with the seal and press in a new bushing and seal (figure 6.16). Press in the new seal using a tube with a diameter approximately equal to the seal diameter. The seal should be hidden in the shaft to a depth of 0.8 to 1.3 mm



2. Gear wheels are supplied as spare parts in pairs and must also be replaced in case of breakage.

3. Control of synchronizer units is described in paragraph 16.

4. When installing the input shaft, it is necessary to lightly lubricate all parts.

5. The input shaft must be assembled in the reverse order of disassembly. It is necessary to pay attention that such elements as the synchronizer hub or the sliding clutch are facing the appropriate direction.

6. The installation is completed after the 4th speed gear is installed. Install the spacer washer between the gearbox housing and the ball bearing (if there was one), the ball bearing and bearing disc are inserted into the housing and screwed with three bolts with splined sockets. The gearbox housing with the installed ball bearing is placed on the input shaft only after all the elements inside the box have been assembled.



7. It should be noted that the axial clearance of the input shaft is not adjustable and the thickness of the bearing spacer washer remains constant.

Output shaft

The output shaft is installed in the reverse order of dismantling.

8. If it is necessary to replace the output shaft, the large pinion of the main transmission should also be replaced, since these elements form a set. Replace the pinions of the main transmission, and repair of the differential mechanism, as noted earlier, is carried out at a specialized enterprise.