Pinion Shaft and Hollow Shaft, Disassembling and Assembling
Pinion shaft and hollow shaft, disassembling and assembling - 6 Spd. Manual Transmission 02X All Wheel Drive
Note:
^ Removing and installing gear wheels for 3rd to 6th gear and the reverse selector gear is described in chapter on disassembling and assembling transmission Go To Disassembling and assembling sequence Disassembling and Assembling Sequence.
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Thrust disc VW 412
^ Tube VW 415 A
^ Thrust ring VW 470
Special tools, testers and auxiliary items required
^ Sleeve VW 519
^ Press tool 40 - 21
^ Tube 2040
^ Thrust piece 2050
^ Thrust pad 3062
^ Press tool 3118
Special tools, testers and auxiliary items required
^ Sleeve 3144
^ Wheel bearing assembly set 3253
^ Tube for wheel bearing 3345
^ Hot air blower V.A.G 1416
^ - 1 - Internal puller Kukko 21/8
^ - 3 - Splitter Kukko 17/2
^ - 4 - Counter-support Kukko 22/2
^ Feeler gauge
Pulling out double tapered roller bearing outer race
- Removing differential.
- Install thrust piece 2050 with large diameter pointing toward outer race.
- Install threaded spindle and thrust pad of wheel bearing assembly set 3253 with thrust plate VW 401 onto transmission housing.
The outer race will be pulled out of transmission housing when nut is tightened.
Pressing off double tapered roller bearing inner race
- Remove circlip before pressing off.
- The outer race of double tapered roller bearing - A - must be installed prior to pressing off inner race.
Pressing on double tapered roller bearing inner race
- Heat inner race to approx. 100 degrees C and press on.
- Determine thickness of required circlip and install circlip.
Determining thickness of circlip
- Determine thickest circlip that will just fit and install it.
Note:
^ The circlips for the synchronizing hubs and individual gear wheels should also be determined as shown for the double tapered roller bearing.
The following circlips are available:
Heating transmission housing in order to install double tapered roller bearing outer race
- Heat transmission housing in area of bearing seat for approx. 15 minutes, to approx. 100 degrees C, with hot air blower V.A.G 1416.
Pressing in double tapered roller bearing outer race
- Insert outer race only after heating transmission housing and push into position under workshop press until heat exchange has taken place.
Pulling tapered roller bearing outer race out of bearing housing
A - Counter-support, e.g. Kukko 22/2
B - Internal puller 56 to 70 mm, e.g. Kukko 21/8
Pressing tapered roller bearing outer race into bearing housing
Support bearing housing with sleeve 3144 directly below bearing mounting.
- Press in outer race until limit stop.
Disassembling and assembling hollow shaft
Pressing off thrust washer for reverse selector gear
A - Splitter 22 to 115 mm, e.g. Kukko 17/2
Note:
^ Install splitter - A - below thrust washer, and not below circlip.
- Then detach circlip below thrust washer.
Pressing off tapered roller bearing inner race with 2nd speed selector gear
A - Splitter 22 to 115 mm, e.g. Kukko 17/2
Note:
^ When pressing off, make sure that only the gear teeth of the selector gear and not the gear shift splines contact the splitter - A -. Otherwise the gear shift splines will be damaged.
- Remove circlip for tapered roller bearing inner race.
Pressing off 1st and 2nd gear synchronizing hub
- Remove circlip before pressing off.
- Place selector gear in center of thrust ring VW 470 to press off synchronizing hub with 1st speed selector gear.
Installation position of circlips
- The required circlips for synchronizing hubs, needle bearings and individual gear wheels should be selected as shown in
^ Circlip - 1 - secures the 1st and 2nd gear synchronizing hub.
Identification: blue color
^ Circlip - 2 - secures tapered roller bearing inner race.
^ Circlip - 3 - secures thrust washer for reverse selector gear.
^ Circlip - 4 - secures the 3rd gear wheel.
^ Circlip - 5 - secures the 6th gear wheel.
- Determine circlips according to table.
Installation position of synchronizing rings for 1st and 2nd gear:
Note:
^ If components are not being replaced, make sure they are re-installed on same gear.
- Install inner ring - 2 - onto selector gear - 1 -.
- Install intermediate ring - 3 -. Lug - B - must be inserted into recess - A -.
- Synchro-ring - 4 - installed. Guide tabs - C - through recess - arrow -.
Checking 1st gear inner ring for wear
- Check outer contact surface - arrow - for scoring or visible traces of wear and replace if necessary.
- Press inner ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.
Checking 1st and 2nd gear intermediate ring for wear
- Check inner contact surface of synchro-ring for scoring or visible traces of wear and replace if necessary.
- Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.
Pressing on 1st and 2nd gear synchronizing hub
^ Installation position:
High inside collar faces 2nd gear.
^ The tabs of 1st gear synchro-ring and recesses on synchronizing hub must align - arrow - when pressing on.
Assembling 1st and 2nd gear locking collar/synchronizing hub
- Install locking pieces - arrows A - into mounted synchronizing hub - 1 -.
- Install locking collar - 2 - onto synchronizing hub so that the wide splines of locking collar and synchronizing hub - arrow B - coincide.
- Install circlip for 1st and 2nd gear synchronizing hub.
- Install 2nd speed selector gear with needle bearing and synchro-rings.
- Install circlip for tapered roller bearing inner race onto hollow shaft.
Pressing on tapered roller bearing inner race
^ Shoulder of tube VW 415 A faces inner race - arrow -.
Then check axial play of 1st speed and 2nd speed selector gears.
Checking axial play of selector gears
- Check axial play of selector gears between hollow shaft - 2 - and 1st speed selector gear - 3 - and also between 2nd speed selector gear - 4 - and tapered roller bearing inner race - 5 - using feeler gauge - 1 -.
^ The play must be 0.20 to 0.50 mm.
Pressing on thrust washer for reverse selector gear
- Install circlip - B - onto hollow shaft.
- Press on thrust washer - A - until it makes contact with circlip.