Secondary shaft installation (VW Golf 2)

When both tapered bearings are removed from the secondary shaft, they become unusable. Therefore, the cover with the bearing on one side of the shaft should be replaced, and the outer race of the bearing in the lower crankcase on the other. Then adjust the axial clearance again. On the 020 (4R) gearboxes, the method of installing the needle bearing in the housing was changed. Limiter 1 (see figure 340) the needle bearing was replaced with a special bolt, and a threaded hole appeared in the gearbox housing. If old parts are installed, lubricate the bearings and insert the shaft into the gearbox housing (attached to the engine). Install the bearing cap correctly, as its displacement will prevent the installation of the reverse gear pinion. If the bearings are new, they should be heated in an oil bath to 100°C and put on the secondary shaft from the appropriate sides. Figure 347 shows the method for installing the bearings. The inner race of the lower bearing should be well secured.



Check the condition of the synchronizer locking ring and install the synchronizer in the manner, described here.



Place spring washer 12 on the shaft (see figure 340) with the shoulder facing the bearing cap. Put on the 10 I gear pinion with a well-lubricated needle bearing.

Heat the hub of the 1st/2nd gear synchronizer with ring 9 to 120°C and install it on the shaft using a piece of pipe.

Place the inner race of the needle bearing onto the shaft until it stops against the gear.

Place the 2nd gear pinion on the needle bearing.

Heat the third gear pinion and install it on the shaft so that its shoulder is directed towards the second gear pinion. Insert the retaining ring into the groove.

Measure the clearance between the third gear pinion and the retaining ring (figure 348). The gap should be as small as possible and be in the range of 0-0.20 mm. Retaining rings are available in different thicknesses in the range from 2.5 to 3.0 mm.



Install the IV gear 3 (see figure 340) with the ledge facing upwards and install a new retaining ring 2. As stated earlier, limiter 1 may be missing.

Screw the bolt into the threaded hole of the reverse gear shaft. Insert the shaft into the hole of the crankcase and position it so that the head of the bolt points to a point equidistant from both holes for the crankcase mounting bolts (the dimensions "x" on both sides must be the same - see Figure 349). In this position, press the shaft into the bearing cover until it stops.