Pinion and Hollow Shaft, Disassembling and Assembling

Pinion and hollow shaft, disassembling and assembling

Special tools and workshop equipment required
^ VW 401 Pressure plate
^ VW 402 Pressure plate
^ VW 407 Press tool
^ VW 411 Press tool
^ VW 412 Press tool
^ VW 415 A Tubular section

^ VW 416 B Tubular section
^ VW 418 A Tubular section
^ VW 429 Thrust collar
^ VW 447 i Thrust pad
^ VW 454 Pressure piece
^ VW 519 Tubular section

^ VW 771 Multi-purpose tool
^ 40-103 Base
^ 2010 Tubular section
^ 3062 Thrust pad
^ 3128 Puller
^ Kukko 17/2 Separating tool
^ Kukko 21 /1 Internal puller

Note:
^ Observe technical data when installing new gear wheels or drive unit.
^ When replacing parts marked 1) adjustments are required go to Adjustment table.

1 - Transmission housing
2 - Shim S3
^ Adjustment table
3 - Outer race for double tapered roller bearing 1)
^ Replace together with -item 5 -
^ Extracting
^ Pressing in
4 - Pinion 1)
^ Paired with ring gear, replace as assembly
^ Adjusting pinion and ring gear
5 - Inner race for double tapered roller bearing 1)
^ Replace
^ Gets damaged on removal
^ Pressing off
^ Pressing on
6 - Circlip Determine thickness when replacing double tapered roller bearing
7 - Needle bearing
^ For pinion in hollow shaft
^ Lubricate with MoS2 grease
8 - Hollow shaft 1)
9 - Needle bearing for 1st gear
10 - Needle bearing for 1st gear
11 - 1st gear sliding gear
12 - Spring
^ Inserting in 1st gear sliding gear
^ Assignment to sliding gear Parts catalog
13 - 1st gear synchro-ring
^ Checking for wear
14 - 1st and 2nd gear synchro-hub
^ Pressing off
^ Pressing on
15 - Circlip
^ Mark
^ Installation position - item 1
^ Re-determining when replacing synchro hub
16 - Needle bearing for 2nd gear
17 - 1st and 2nd gear locking collar
^ Installation position
18 - 2nd gear synchro-ring
^ Checking for wear
19 - Spring
^ Inserting in 2nd gear sliding gear Fig. 16
^ Assignment to sliding gear Parts catalog
20 - 2nd gear sliding gear
21 - Circlip
^ Mark
^ Installation position item 2
22 - 3rd gear wheel
^ Pressing off
^ Pressing on
23 - Circlip
^ Mark
^ Installation position item 3
^ Re-determining when replacing 3rd gear wheel
24 - 4th gear wheel
^ Pressing off
^ Pressing on
25 - Circlip
^ Mark
^ Installation position - item 4
^ Re-determining when replacing 4th gear wheel
26 - Needle bearing
27 - 5th gear sliding gear
28 - Spring
^ Inserting in 5th gear sliding gear
^ Assignment to sliding gear
go to Parts catalog
29 - 5th gear synchro-ring
^ Checking for wear
30 - Circlip
^ Mark
^ Installation position - item 5
31 - Synchro-hub 5th gear and reverse gear
^ Pressing off
^ Pressing on
32 - Circlip
^ Mark
^ Installation position - item 6
^ Re-determining when replacing synchro hub
33 - Needle bearing
^ For reverse gear
34 - Locking collar for 5th gear and reverse gear
^ Installation position
35 - Reverse gear synchro-ring
^ Checking for wear
36 - Spring
^ Inserting in reverse gear sliding gear
^ Assignment to sliding gear Parts catalog
37 - Reverse gear sliding gear
38 - Circlip
^ Mark
^ Installation position - item 7
39 - Inner race for tapered roller bearing
^ Pressing off
^ Pressing on
40 - Bushing
^ for securing outer race of small tapered roller bearing
^ Extracting
^ Does not need to be installed after small tapered roller bearing has been replaced
41 - Outer race for tapered roller bearing 1)
^ Pressing out
^ Pressing in
42 - Shim S4
^ Adjustment table
43 - Ring
^ For holding rubber washer
^ Assignment
go to Parts catalog
44 - Rubber washer
^ For length compensation
^ Assignment
^ Parts catalog
45 - Transmission cover

Fig. 1 Extracting outer race for double tapered roller bearing:

- Removing differential.
- Position pressure piece of puller 3128 beneath outer race.
- Install threaded section of puller 3128 together with pressure plate VW 401 onto transmission housing.
When bolt is tightened, outer race is pulled out of housing.

Fig. 2 Pressing off inner race for double tapered roller bearing:

- Remove circlip before pressing off.
- Outer race -A- must be mounted before inner race can be removed.

Note: Inner race of double tapered roller bearing will be destroyed during pressing off.

Fig. 3 Pressing in outer race for double tapered roller bearing:

Smaller diameter of thrust pad 3062 faces outer race.

Fig. 4 Pressing on inner race for double tapered roller bearing:

Fig. 5 Determining circlip:

- Determine and install thickest circlip which can still just about be inserted.
- Circlips for synchro-hubs, needle bearings and gear wheels of individual gears also need to be determined as shown for double tapered roller bearing.
Available circlips and their part numbers:
go to Parts catalog

Fig. 6 Pulling out locking bushing for outer race of small tapered roller bearing:

A - Internal puller, e. g. Kukko 21/1, 12 to 16 mm

Fig. 7 Pressing out outer race for tapered roller bearing:

- Outer race is pressed out together with ring -item 43 -, shim S4 -item 42 - and rubber washer for length compensation -item 44 -.

Fig. 8 Pressing in outer race for tapered roller bearing:

Fig. 9 Pressing off inner race for tapered roller bearing:

- Press off inner race together with reverse gear sliding gear.
A - Separating tool 22 to 115 mm, e.g. Kukko 17/2

Fig.10 Pressing on inner race for tapered roller bearing:

- Install circlip before pressing on inner race.

Fig.11 Pressing off 5th gear and reverse gear synchro-hub:

- Remove circlip before pressing off.
- Press off synchro-hub together with 5th gear sliding gear.
A - Separating tool 22 to 115 mm, e.g. Kukko 17/2

Fig. 12 Pressing off 4th gear wheel:

- Remove circlip before pressing off.

Fig. 13 Pressing off 3rd gear wheel:

- Remove circlip before pressing off.
- Press off 3rd gear wheel together with 2nd gear sliding gear.
A - Separating tool 22 to 115 mm, e.g. Kukko 17/2

Fig. 14 Pressing off 1st and 2nd gear synchro-hub:

- Remove circlip before pressing off.
- Press off synchro-hub together with 1st gear sliding gear.

Fig. 15 Installation position of circlips:

- Circlips for synchro-hubs, needle bearings and gear wheels of individual gears also need to be determined as shown in.
- Circlip -1- secures synchro-hub for 1st and 2nd gear.

Identifiable by: Color blue

^ Circlip -2- secures 2nd gear needle bearing/sliding gear.

Identifiable by: Color blue

^ Circlip -3- secures 3rd gear wheel.

^ Circlip -4- secures 4th gear wheel.
^ Circlip -5- secures 5th gear needle bearing/sliding gear.

Identifiable by: Color brown

^ Circlip -6- secures synchro-hub for 5th gear and reverse gear.

Identifiable by: Color blue

^ Circlip -7- secures needle bearing for reverse gear sliding gear.

- If necessary determine circlips using chart. Part numbers
go to Parts catalog

Fig. 16 Inserting spring into sliding gear:

Bent end of spring (arrow) must be hooked into hole of sliding gear.

Fig. 17 Checking synchro-ring for wear:

- Push synchro-ring into locking collar and use feeler gauge to measure gap -a- at positions -A-, -B- and -C,
- Add up measured values and divide by 3.
Obtained value must not be lower than 0.5 mm.

Fig. 18 Pressing on synchro-hub for 1st and 2nd gear:

^ Installation position:
High collar on inside faces 2nd gear

Fig.19 Installation position of locking collar for 1st and 2nd gear:

^ Installation position:
Chamfer -arrow 1 - faces 2nd gear
Shoulder -arrow 2- faces 1st gear

Fig. 20 Pressing on 3rd gear wheel:

^ Installation position:
Groove on gear wheel faces 4th gear

Fig. 21 Pressing on 4th gear wheel:

^ Installation position:
High collar on inside faces 3rd gear

Fig. 22 Pressing on synchro-hub for 5th gear and reverse gear:

^ Installation position:
High collar on inside faces 5th gear

Fig. 23 Installation position of locking collar for 5th gear and reverse gear:

Locking collars with chamfer -A- and locking collars with high shoulder -B- are used for assembly.
^ Note locking collar assignment to reverse idler gear
^ Installation position:
Chamfer -arrow 1 - faces reverse gear
Low shoulder -arrow 2- faces 5th gear
High shoulder -arrow 3- faces reverse gear