Replacing transmissions normally requires the support of know onions technicians.
Rebuilding the transmission of your 1.8 Litre Volkswagen Jetta may save you a appreciable proportions of method. The payment To possess someone else occupation on the transmission of your vehicle can be fee prohibitive, regardless of the assemble or mannequin. With foreign-made cars the costs can be much higher due to the unavailability of parts and experienced technicians to grindstone on the transmission.
Instructions
Removal
1. Prepare the transmission for Emigration by mounting the Jetta's transaxle in a mounting fixture and installing a shaft brace bridge.
2. Void the gearbox for the oil and hire the clutch push rod elsewhere of the Jetta's input shaft.
3. Remove the housing comprehend bolts with a wrench or a ratchet. Yield away the shaft lock fan, the vehicle velocity sensor, the selector shaft include and spring.
4. Berth the selector forks in the impartial position and pull gone the selector shaft. Remove the reverse loafer gear shaft by captivating elsewhere the Torx bolt.
Install a new circlip here also. Put in the deep groove ball bracket and then install the tension bracket and then the selector into the clutch housing. Install the shift forks, including the fork for the reverse gear. Put the selector rod in position and then ensure that the reverse idler gear shaft is properly aligned.
Returns elsewhere the retaining bolt for the synchronizing hub and the plate that secures the selector tube. Remove the shift fork by turning the selector tube counter-clockwise. Pry outside the fifth gear, shift fork and synchronizer hub all these days. Pry carefully to avoid damage.
7. Receive off the tension bracket on the immersed groove ball bearing located on the input shaft. Remove the shift fork after ahead pulling the selector rod. Haul off the fourth clip from the output shaft. Assemble firm that the transmission is not in reverse and then booty outside the input shaft meeting, along with the moment and third gear, synchronizer bell and pointer bearings. Knock elsewhere the reverse gear shaft by butting a bolt against it and hitting the bolt with a plastic hammer or rubber mallet.
8. Remove the reverse gear, synchronizer hub, head gear and moment gear inner thorn. As well share off the involve bolts for the bearings, along with the thrust washer and encompass. Additionally remove the output shaft, operate flange on the conscientious side, differential meeting, tapered call and thrust washer.
Assembly
9. Levy the differential into the clutch housing and then install both the bearing insert and the output shaft. Tighten the output shaft bearing comprehend to 30 foot-pounds of torque. Very install the inner thrust washer, synchronizer hub, inaugural and moment gear thorn bearing inner contest on the output shaft. The synchronizer hub should then be heated to approximately 212 degrees Fahrenheit.
10. Install the bearing competition for the moment gear bodkin, along with the darner bearings, moment and third gear and the synchronizer bell. Make sure that the moment gear is facing the shoulder. Install a recent circlip extremely.
11. Situate the input shaft into the clutch housing and then replace the fourth gear with the shoulder facing the fifth gear.5. Grip gone the manage flange comprehend, washer and circlip and then pull absent the operate flange.6. Engage and reverse the transmission's fifth gear.
12. Reinstall the housing for the transmission, ensuring that the support bridge provides enough support to do the job properly. Place the Torx bolt into the gear shaft for the idler and tighten it to 15 foot-pounds of torque. Secure the housing with hex head bolts, torquing each one to 18 foot-pounds. Tighten the tension bracket for the deep groove bearing to 11 foot-pounds.
13. Heat the fifth gear to 212 degrees and then install it, along with the thrust washer and the appropriate-sized circlip.
14. Turn the shift tube in a clockwise direction using a tube wrench and then engage both the fifth gear and reverse. Thread the bolts of the synchronizer hub bolt using threadlocker. Tighten it to 111 foot-pounds of torque. Place the shift fork in the neutral position and then insert both the selector shaft and the selector shaft spring before covering them with a new seal seal ring. Tighten this assembly to 47 foot-pounds.
15. Add sealant to the selector shaft lock bolt and then tighten to 30 foot-pounds of torque. Adjust the selector fork for the fifth gear, but be careful that you don't cause the transmission to come out of gear in the process. Check and adjust the shift tubes. Attach the gear selector lever onto the selector shaft by bolting it in place. Engage the fifth gear. Raise the operating sleeve and the shift fork, if necessary, to compensate for any free play between the various components.
16. Make adjustments, as necessary, and ensure that the synchronizer ring can move freely. Use a new securing plate to ensure that shift fork is supported and then release the tension on the support bridge. Install the clutch pushrod by pushing it through the end of fifth gear first. Also install the clutch release bearing, the housing cover gasket and the cover.
17.Ensure that all gears shift properly and then finally install the drive flanges, flange covers, dished washers and circlips to finish the job.
