Output Shaft, 1st to 4th Gears
Output Shaft, 1st to 4th Gears
Special tools, testers and auxiliary items required
• Pressure Plate (VW 401)
• Pressure Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Punch (VW 412)
• Sleeve (VW 415 A)
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Piece (VW 431)
• Thrust Piece (VW 433)
• Thrust Piece (VW 454)
• Thrust Pad (VW 512)
• Sleeve (VW 516)
• Sleeve (VW 519)
• Slide Hammer (VW 771)
• Holding Plate (VW 801)
• Thrust Piece (40 - 105)
• Seal Driver-Front Wheel Bearing (40-20)
• Seal Driver-Front Wheel Bearing (40-21)
• Thrust Piece (2050)
• Spacers (VW 540/1 B)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment (V.A.G 1582/7)
• Internal Puller (Kukko 21/7)
• Internal Puller (Kukko 21/8)
• Puller (Kukko 18/2)
• Separating Tool (Kukko 17/2)
• Counter-Support (Kukko 22/2)
Pull Dished Washer - A - Off Output Shaft
Pressing Dished Washer into Output Shaft
Dimension "a" = 2 mm
Pulling Out the Outer Race for Tapered Roller Bearing
A Counter Support (Kukko 22/2)
B Internal Puller 56 to 70 mm (Kukko 21/8)
Pressing Outer Race for Tapered Roller Bearing into Clutch Housing
- Support the clutch housing with the Sleeve (40 - 20) directly under the bearing mount.
Pulling Off Inner Race for Tapered Roller Bearing
- Before pulling off, remove circlip.
- Before attaching extractor, place Thrust Piece (VW 431) and Thrust Plate (40 - 105) on input shaft.
Pulling Off Locking Collar/Synchronizer Hub For 3rd and 4th Gear with Selector Gear for 4th Gear
- Before pulling off, remove circlip.
A Puller (Kukko 18/2)
B Separating Device 22 to 115 mm (Kukko 17/2)
Pressing Off Locking Collar/Synchronizer Hub for 1st and 2nd Gear with Selector Gear for 2nd Gear
- Remove circlip.
- Press off selector gear and locking collar/synchronizer hub all together.
Pressing Off Inner Race for Tapered Roller Bearing
A Separating Device 22 to 115 mm (Kukko 17/2)
Pressing On Tapered Roller Bearing Inner Race
Checking Inner Race for 1st, 2nd and 3rd Gear for Wear
- Press inner race onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Checking Synchronizer Rings for 1st, 2nd or 3rd Gears for Wear
- Press synchronizer ring, outer race and inner race onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Installed Position of Outer Race, Inner Race and Synchronizer Ring for 2nd Gear
- Place inner race - A - on the 2 gear wheel.
• The bent tabs - arrows 1 - face toward outer race - B -.
- Set outer race - B - in place.
• The tabs - arrows 2 - engage in the grooves - arrows 3 - of the selector gear.
- Install synchronizer ring - C -.
• The grooves - arrows 4 - engage in the tabs - arrows 1 - of the inner race - A -.
Disassembling and Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears, as Well as 3rd and 4th Gears
- Remove the springs to disassemble - 1 -.
2 Locking piece
3 Locking collar
4 Synchronizer hub
- To assemble, slide locking collar over the synchronizer hub.
• Installation position: The narrow recesses in the synchronizer hub align with the recesses in the locking collar.
Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears, as Well as 3rd and 4th Gears
• The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset.
• Spring must engage with angled end into hollow engaging piece.
Installation Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
• The identification groove - arrow 1 - and thin collar - arrow 2 - of synchronizer hub point to 1st gear.
Pressing On Locking Collar/Synchronizer Hub for 1st and 2nd Gear
- Then install circlip.
Installation Position of Outer Race For 1st and 3rd Gear
• The tabs - arrows - face toward locking collar/synchronizer hub - A -.
Installation Position of Synchronizer Ring - A - (Inner Race For 1st and 3rd Gear)
• The tabs - arrows 1 - engage into the recesses - arrows 2 - of the synchronizer ring - B -.
Installation Position of Selector Gear for 1st and 3rd Gear
• The higher collar - A - faces 2nd and 4th gear - B -. The cut-outs in the collar - arrows - engage into outer race tabs. Refer to => [ Installation Position of Outer Race For 1st and 3rd Gear ].
Installation Position of Locking Collar/Synchronizer Hub for 3rd and 4th Gear
• Wider collar of synchronizer hub - arrow - points to 3rd gear.
Pressing on Locking Collar/Synchronizer Hub for 3rd and 4th Gears
- Then install circlip.
Checking Synchronizer Ring for 4th Gear for Wear
- Press synchronizer ring onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Pressing on Tapered Roller Bearing Inner Race
- Then, determine the circlip.
Determining Circlip
- Select and install the thickest, but yet still installable, retaining ring; for the part number, refer to the Parts Catalog.
The following circlips are available:
Pulling Outer Race for Tapered Roller Bearing Out of Transmission Housing
A Counter Support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)
Pressing Outer Race for Tapered Roller Bearing into Transmission Housing
- Install shim under outer race.
- Support the transmission housing with the Thrust Plate (2050) under the bearing mount.