Output Shaft For 5th/6th and Reverse Gear, Disassembling and Assembling
Output shaft for 5th/6th and reverse gear, 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 VW 412
^ Tube 60 mm dia. VW 415 A
Special tools, testers and auxiliary items required
^ Holding plate VW 309
^ Transmission support VW 353
^ Thrust pad con. 8/65 VW 433
^ Thrust tube VW 454
^ Support channels VW 457
^ Holding fixture VW 801
Special tools, testers and auxiliary items required
^ Thrust pad 16.5/28 mm dia. VW 431
^ Thrust tube VW 455
^ Thrust pad VW 510
^ Tube 42 mm dia. VW 516
^ Sleeve VW 519
^ Thrust piece 30-11
Special tools, testers and auxiliary items required
^ Thrust piece 40-105
^ Fitting sleeve 40-20
^ Thrust piece 2050
^ Press device 3235
^ Line 3296
^ Taper roller bearing puller V.A.G 1582
^ Attachment V.A.G 1582/4
Special tools, testers and auxiliary items required
^ Attachment V.A.G 1582/7
^ - 1 - Internal extractor Kukko 21/7
^ - 3 - Separating tool Kukko 17/2
^ - 4 - Support Kukko 22/2
Note:
^ Observe technical data when installing new gears or new output shaft.
^ When replacing output shaft or tapered roller bearing, output shaft must be adjusted.
1 - Clutch housing
2 - Washer
^ 0.65 mm thick
3 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
4 - Inner race for tapered roller bearing
^ Pulling off
^ Pressing on
5 - Output shaft
^ For 5th/6th and reverse gears
^ Adjusting Output shaft for 5th/6th and reverse gears, adjusting
6 - Synchronizer hub for reverse gear
^ Pressing off
^ Installed position
^ Pressing on
7 - Circlip
8 - Operating sleeve for reverse gear
^ With synchronizer ring
9 - Needle bearing
^ For gear wheel for reverse gear
10 - Reverse gear
11 - Sleeve
^ Pressing off over gear wheel for reverse gear
^ Installed position: Wider collar on sleeve points toward gear wheel for reverse gear
^ Pressing on
12 - Circlip
13 - Needle bearing
^ For 6th gear
^ Does not apply to 5 speed manual transmission
14 - 6th gear
^ Does not apply to 5 speed manual transmission
15 - Synchronizer ring for 6th gear
^ Does not apply to 5 speed manual transmission
^ Checking for wear
16 - Spacer sleeve
^ For 5 speed manual transmission
^ Position toward operating sleeve/synchronizer hub for 5th gear
^ Press on 5th gear together with operating sleeve/synchronizer hub
17 - Operating sleeve with synchronizer hub for 5th and 6th gears
^ Disassembling
^ Assembling operating sleeve/synchronizer hub and
^ Pressing on with 6 speed manual transmission
^ Pressing on with 5 speed manual transmission
18 - Circlip
19 - Needle bearing
^ For 5th gear
20 - Synchronizer ring for 5th gear
^ Checking for wear
21 - 5th gear
22 - Inner race for tapered roller bearing
^ Pulling off
^ Pressing on
23 - Circlip
24 - Tapered roller bearing outer race
^ Pulling out
^ Pressing in
25 - Adjustment shim
^ Determining thickness Output shaft for 5th/6th and reverse gears, adjusting
26 - Transmission housing
27 - Spring
^ Installed position
28 - Operating sleeve
29 - Synchronizer
30 - Engagement pieces
^ Qty. 3
^ Installed position
Pulling out tapered roller bearing outer race
A - Support Kukko 22/2
B - Internal puller 46 to 58 mm Kukko 21/7
Note: After pulling off, check shim for damage and replace if necessary.
Pressing in outer race/tapered roller bearing into clutch housing
- First, place shim beneath outer race first.
- Support transmission housing directly beneath bearing mount using Sleeve 40-20.
Pulling off inner race for tapered roller bearing
- First remove seal.
- Before attaching extractor, place Thrust pad VW 431 and thrust piece 40-105 on output shaft.
Pressing off synchronizer hub/operating sleeve for 5th and 6th gear with gear wheel for 6th gear
- First remove seal.
Pressing off synchronizer hub/operating sleeve 5th gear with spacer sleeve
- First remove seal.
Pressing off sleeve over gear for reverse gear
- Remove circlip before pressing off sleeve - A -.
Pressing off synchronizer hub for reverse gear
- A - Separating tool 22 to 115 mm Kukko 17/2.
Pulling off inner race for tapered roller bearing
- Before attaching extractor, place Thrust pad 30-11 on output shaft.
Installed position of synchronizer hub for reverse gear
^ Stop - arrow A - for reverse gear operating sleeve points toward output shaft splines - arrow B -.
Pressing on synchronizer hub for reverse gear
- Install circlip after pressing on.
Pressing on sleeve
^ Installed position: Wide collar points toward gear for reverse gear.
- Install circlip after pressing on sleeve - A -.
Checking synchronizer ring for 5th and 6th gears 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.
Disassembling and assembling operating sleeve and synchronizer hub for 5th and 6th 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/synchronizers for 5th and 6th 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.
Pressing on operating sleeve/synchronizer hub for 5th and 6th gears
- Install circlip after pressing on.
Position spacer sleeve toward operating sleeve/synchronizer hub for 5th gear
^ Spacer sleeve tabs - arrow 1 - must line up with recesses of synchronizer hub - arrow 2 -.
^ Engagement pieces - arrow 3 - must rest on spacer sleeve collar.
Pressing on operating sleeve/synchronizer hub 5th gear with spacer sleeve
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.
Pressing on inner race of tapered roller bearing
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
- Support transmission housing beneath bearing mount using pressure plate 2050.