1st to 4th Gear Output Shaft, Disassembling and Assembling
1st to 4th gear output shaft, disassembling and assembling, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Punch VW 408 A
^ Thrust Disc VW412
^ Tube 60 mm Dia. VW415A
Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Holding fixture VW 313
^ Transmission support VW 353
^ Thrust Pad 16.5/28 mm Dia. VW 431
^ Thrust Pad Con. 8/65 VW 433
^ Thrust Tube VW 454
Special tools, testers and auxiliary items required
^ Thrust pad VW 512
^ Tube 42 mm Dia. VW516
^ Sleeve VW519
^ Slide Hammer-Complete Set VW771
^ Holding Fixture VW801
^ Thrust piece 40-105
Special tools, testers and auxiliary items required
^ Sleeve 40-20
^ Sleeve 40-21
^ Thrust plate 2050
^ Extension 3161
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/7
^ - 1 - Internal extractor Kukko 21/7 and Kukko 21/8
^ - 2 - Puller Kukko 18/2
^ - 3 - Separating tool Kukko 17/2
^ - 4 - Support Kukko 22/2
Output shaft 1st to 4th gear, assembly overview
Note:
^ Observe technical data when installing new gears or new output shaft Code letters, assembly allocation, ratios, capacities.
^ When replacing output shaft or tapered roller bearing, output shaft must be adjusted Output shaft for 1st to 4th gear, adjusting.
1 - Clutch housing
2 - Oil deflector ring
3 - Dished washer
^ Pulling out
^ Pressing in
4 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
5 - Inner race for tapered roller bearing
^ Pressing off
^ Pressing on
6 - Output shaft
^ For 1st to 4th gear
^ Adjusting Output shaft for 1st to 4th gear, adjusting
7 - Needle bearing
^ For 2nd gear
8 - 2nd gear
9 - Synchronizer ring
^ Inner race for 2nd gear
^ Checking for wear
^ Checking tabs for signs of wear
^ Installed position
10 - Outer race for 2nd gear
^ Replace if scored or show signs of wear
^ Installed position
11 - Synchronizer ring for 2nd gear
^ Checking for wear
^ Installed position
12 - Operating sleeve with synchronizer hub for 1st and 2nd gears
^ Disassembling
^ Assembling operating sleeve/synchronizer hub and
^ Installed position
^ Pressing on
13 - Circlip
14 - Synchronizer ring for 1st gear
^ Checking for wear
15 - Outer race for 1st gear
^ Replace if scored or show signs of wear
16 - Synchronizer ring
^ Inner race for 1st gear
^ Checking for wear
^ Checking tabs for signs of wear
^ Installed position
17 - Needle bearing
^ For 1st gear
18 - 1st gear
^ Installed position
19 - Pressure plates
^ For 1st and 4th gear
^ Insert tabs of thrust washer in output shaft hole
20 - Washer
21 - Needle bearing
^ For 4th gear
22 - 4th gear
23 - Synchronizer ring for 4th gear
^ Checking for wear
24 - Operating sleeve with synchronizer hub for 3rd and 4th gears
^ Disassembling
^ Installed position of operating sleeve/synchronizer hub
^ Assembling operating sleeve/synchronizer hub and
^ Pressing on
25 - Circlip
26 - Synchronizer ring for 3rd gear
^ Checking for wear
27 - Outer race for 3rd gear
^ Replace if scored or show signs of wear
28 - Synchronizer ring
^ Inner race for 3rd gear
^ Checking for wear
^ Checking tabs for signs of wear
^ Installed position
29 - Needle bearing
^ For 3rd gear
30 - 3rd gear
^ Installed position
31 - Inner race for tapered roller bearing
^ Pulling off
^ Pressing on
32 - Circlip
33 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
34 - Adjustment shim
^ Determining thickness Output shaft for 1st to 4th adjusting
35 - Transmission housing
Pull dished washer - A - off output shaft
Pressing dished washer in output shaft to stop
Pulling out tapered roller bearing outer race
A - Support Kukko 22/2
B - Internal puller 56 to 70 mm Kukko 21/8
Pressing in outer race/tapered roller bearing into clutch housing
- Support transmission housing directly beneath bearing mount using Sleeve 40-20.
Pulling off inner race for tapered roller bearing
- Before attaching extractor, place Thrust pad VW 431 in output shaft and place Thrust piece 40-105 above.
Pulling off synchronizer hub/operating sleeve for 3rd and 4th gear over gear wheel for 4th gear
- First remove seal.
A - Puller Kukko 18/2
B - Separating tool 22 to 115 mm Kukko 17/2
Pressing off operating sleeve and synchronizer hub for 1st and 2nd gears
- First remove seal.
- Press off 2nd gear together with operating sleeve/synchronizer hub.
Pressing off inner race for tapered roller bearing
A - Separating tool 22 to 115 mm Kukko 17/2
Pressing on inner race of tapered roller bearing
Checking inner race for 1st gear, 2nd gear and 3rd gear for wear
- Press inner race onto cone of gear and measure gap dimension - a - using a feeler gauge.
^ Installation dimension: 0.75 to 1.25 mm.
^ Wear limit: 0.3 mm.
Checking synchronizer rings for 1st, 2nd and 3rd gears for wear
- Press synchronizer ring, outer race and inner race onto cone of gear and measure gap dimension - a - using a feeler gauge.
^ Installation dimension: 1.2 to 1.8 mm.
^ Wear limit: 0.5 mm.
Installed position of outer race, inner race and synchronizer ring, 2nd gear
- Place inner race - A - on 2nd gear.
^ The bent tabs - arrow 1 - face toward outer race - B -.
- Place outer race - B -.
^ The tabs - arrows 2 - engage in grooves - arrows 3 - of gear wheel.
- Place synchronizer ring - C -.
^ The grooves - arrows 4 - engage in tabs - arrows 1 - of inner race - A -.
Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
1. Spring
2. Engagement piece
3. Operating sleeve
4. Synchronizer
- Slide operating sleeve over synchronizer hub.
^ Recesses for engagement pieces at synchronizer hub and operating sleeve must line up.
Assembling operating sleeve/synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
^ Operating sleeve slid over synchronizer hub.
- Insert engagement pieces and install springs at 120° offset.
^ Spring must engage with angled end into hollow engaging piece.
Installation position of operating sleeve/synchronizers for 1st and 2nd gear
^ The identification groove - arrow 1 - and thin collar - arrow 2 - of synchronizer hub point to 1st gear.
Pressing on operating sleeve/synchronizer hub for 1st and 2nd gear
Installed position of outer race for 1st and 3rd gear
^ Tabs - arrows - point to synchronizer hub/operating sleeve - A -.
Installed position of synchronizer ring - A - (inner race for 1st and 3rd gear)
^ Tabs - arrows 1 - engage into recesses - arrows 2 - of synchronizer ring - B -.
Installed position of gear wheel for 1st and 3rd gear
^ The higher collar - A - points to 2nd and 4th gear - B -.
^ Recesses in collar - arrows - engage into outer race tabs.
Installed position of operating sleeve/synchronizers for 3rd and 4th gear
^ Wider collar of synchronizer hub - arrow - points to 3rd gear.
Pressing on synchronizer hub with operating sleeve for 3rd and 4th gears
Checking synchronizer ring for 4th gear for wear
- Press synchronizer ring onto cone of gear and measure gap dimension - a - using a feeler gauge.
^ Installation dimension: 1.0 to 1.7 mm.
^ Wear limit: 0.5 mm.
Pressing on inner race of tapered roller bearing
- Determine circlip and install.
Determining circlip
- Determine thickest circlip which can still just be installed and insert.
Pulling outer race/tapered roller bearing out of transmission housing
A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7
Pressing in tapered roller bearing outer race into transmission housing
- Place adjustment shim beneath outer race first.
- Support transmission housing beneath bearing mount using pressure plate 2050.