Pinion Shaft, Disassembling and Assembling
Pinion shaft, disassembling and assemblingSpecial tools and workshop equipment required
- VW 401 Press plate
- VW 402 Press plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 412 Press tool
- VW 415A Tube
- VW 204B Crankshaft seal insertion tool
- VW 421 Tube
- VW 455 Fitting sleeve
- VW 519 Tube
- VW 771 Multipurpose tool
- 2010 Tube
- 3005 Press disk
- 3118 Thrust piece
- 3128 Puller
- 3301 Assembly tool
- 1-Kukko 21/4 Internal puller
- 3-Kukko 17/2 Separating device
Notes:
- When installing new gear wheels or the crown wheel and pinion shaft consult technical data.
- If parts are exchanged which affects the position of the taper roller bearings, the pinion shaft must be readjusted.
1. Transmission housing
2. Shim S3
3. Large taper roller bearing outer race
- Pulling out see Fig. 11
- Pressing in see Fig. 12
4. Pinion shaft
- Is mated with crown wheel, always replace together as a set
- Modification: From transmission build date 17088 modified splines for reinforced 4th gear wheel.
5. Large taper roller bearing inner race
- Pressing off see Fig. 10
- Pressing on see Fig. 13
6. Securing clip
- Installation position see Fig. 15, item 1
- Redetermine thickness if taper roller bearing is replaced see Fig. 14
7. Needle roller bearing
- For 1st gear
8. 1st gear sliding wheel
9. Spring
- Insert in 1st gear wheel see Fig. 16
- Allocate to gear wheel from parts catalog
10. 1st gear synchro-ring
- Checking for wear see Fig. 17
11. 1st and 2nd gear synchronizing hub
- Pressing off see Fig. 9
- Higher collar points to 2nd gear
- Pressing on see Fig. 18
12. Securing clip
- Installation position see Fig. 15, item 2
- Redetermine thickness if synchro hub is replaced see Fig. 14
13. Needle roller bearing
- For 2nd gear
14. 1st and 2nd gear locking collar
- Installation position see Fig. 19
15. 2nd gear synchro-ring
- Checking for wear see Fig. 17
16. Spring
- Insert in 2nd gear wheel see Fig. 16
- Allocate to gear wheel from parts catalog
17. 2nd gear wheel
18. Securing clip
- Installation position see Fig. 15, item 3
19. 3rd gear wheel
- Pressing off see Fig. 8
- Groove faces to 4th gear
- Pressing on see Fig. 20
20. Securing clip
- Installation position see Fig. 15, item 4
- Redetermine thickness if 3rd gear wheel is replaced see Fig. 14
21. 4th gear wheel
- Pressing off see Fig. 7
- Collar faces to 3rd gear
- Pressing on see Fig. 21
- Modification: From transmission build date 17088 reinforced.
22. Securing clip
- Installation position see Fig. 15, item 5
- Redetermine thickness if 4th gear wheel is replaced see Fig. 14
- Modification: From transmission build date 17088 modified for reinforced 4th gear wheel.
23. Needle roller bearing
- Modification: From transmission build date 17088 modified for reinforced 5th gear wheel.
24. 5th gear wheel
- Modification: From transmission build date 17088 reinforced.
25. Spring
- Insert in 5th gear wheel see Fig. 16
- Allocate to gear wheel from parts catalog
26. 5th gear synchro-ring
- Checking for wear see Fig. 17
27. Securing clip
- Installation position see Fig. 15, item 6
28. 5th gear and reverse gear synchro-hub
- Pressing off see Fig. 6
- Collar faces to 5th gear
- Pressing on see Fig. 22
29. Securing clip
- Installation position see Fig. 15, item 5
- Redetermine thickness if 5th and reverse gear synchro hub is replaced see Fig. 14
30. Needle roller bearing
- For reverse gear
31. 5th and reverse gear locking collar
- Installation position see Fig. 23
32. Reverse gear synchro-ring
- Checking for wear see Fig 17
33. Spring
- Insert in reverse gear wheel see Fig 16
- Allocate to gear wheel from parts catalog
34. Reverse sliding gear wheel
35. Small taper roller bearing inner race
- Pressing off see Fig. 4
- Pressing on see Fig. 5
36. Bush
- To secure small taper roller bearing outer race
- Pulling out see Fig. 1
- Need not be fitted after the small taper roller bearing has been replaced
37. Small taper roller bearing outer race
- Pulling out see Fig. 2
- Pressing in see Fig. 3
38. Shim S4
39. Pressure plate
- Different thicknesses for aluminum and magnesium transmissions see Fig. 25
40. Disc
- To remove drill hole in disc, screw in self-tapping screw and pull out on self-tapping screw.
- Different thicknesses for aluminum and magnesium transmissions see Fig. 26
- Allocate according to transmission code letters using parts catalog
41. Transmission cover
Fig. 1 Pulling out securing bush for small taper roller bearing outer race
A- Internal extractor 12 to 16 mm, e.g. Kukko 21/1
Fig. 2 Pulling out small taper roller bearing outer race
- Screw special tool VW 771/40 into the pressure plate.
- Attach multi-purpose tool VW 771 and pull outer race out over the pressure plate.
Fig. 3 Pressing in small taper roller bearing outer race
Fig. 4 Pressing out small taper roller bearing inner race
- Press out inner race with reverse gear wheel
A- Separating device 22 to 115 mm, e.g. Kukko
Fig. 5 Pressing on small taper roller bearing inner race
Fig. 6 Pressing off 5th gear and reverse gear synchro hub
- Press off synchro hub with 5th gear wheel
A - Separating device 22 to 115 mm, e.g. Kukko
Fig. 7 Pressing off 4th gear wheel
Fig. 8 Pressing off 3rd gear wheel
- Press gear wheel off with 2nd gear wheel
A - Separating device 22 to 1 15 mm, e.g. Kukko 1 7/2
Fig. 9 Pressing off 1st and 2nd gear synchro-hub
- Press synchro hub off with 1st gear wheel
Fig. 10 Pressing off large taper roller bearing inner race
- The outer race -A- must be fitted to press off the inner race.
Fig. 11 Pulling out large taper roller bearing outer race
- Remove differential
- Place pressure piece of puller 3128 below the outer race.
- Fit threaded spindle and thrust bearing from assembly tool 3301 with pressure plate VW 401 onto transmission housing.
As the nut-arrow- is tightened, the outer race is pulled out of the housing.
Fig. 12 Pressing in large taper roller bearing outer race
The smaller diameter of the special tool VW 204 b faces to outer race.
Fig. 13 Pressing on large taper roller bearing inner race
Fig. 14 Determining thickness of circlip
- Determine the thickest securing clip, which will still fit and install it.
- The circlips for the synchro hubs and individual gear wheels should also be determined as for the taper roller bearing shown.
Fig. 15 Position of circlips
- Circlip -1-, for taper roller bearing inner race.
- Circlip -2-, for 1st and 2nd gear synchro hub.
Identification: Color- blue
Note: Allocate circlip according to parts catalog.
- Circlip -3-, for 2nd gear wheel needle roller bearing.
Identification: Color- blue
- Circlip -4-, for 3rd gear wheel.
- Circlip -5-, for 4th gear wheel.
Note: Allocate circlip according to parts catalog.
- Circlip -6-, for 5th gear needle roller bearing.
Note: Allocate circlip according to parts catalog.
Identification: Color- brown
- Circlip -7-, for 5th and reverse gear synchro hub.
Identification: Color- blue
Note: Allocate circlip according to parts catalog.
Fig. 16 Inserting spring in gear wheel
The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.
Fig. 17 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
- Calculate average gap.
The average gap must not be less than 0.5 mm.
Fig. 18 Pressing on 1st and 2nd gear synchro-hub
Installation position: Higher inner collar faces to 2nd gear.
Fig. 19 Installation position of 1st and 2nd gear locking collar
The chamfer (arrow -1-) faces to 2nd gear.
The stepped side (arrow -2-) faces to 1st gear.
Fig. 20 Pressing on 3rd gear wheel
Installation position: The groove on the gear wheel faces to 4th gear.
Fig. 21 Pressing on 4th gear wheel
Installation position: Higher inner collar faces to 3rd gear.
Fig. 22 Pressing on 5th gear and reverse gear synchro hub
Installation position
Higher inner collar faces to 5th face gear.
The large internal diameter in special tool 2010 faces to synchro hub.
Fig. 23 Installation position of 5th gear and reverse gear locking collar
Note allocation of locking collar to reverse gear wheel see Fig. 24.
Locking collars with chamfer (illustration A, arrow 1) as well as locking collars with deep shoulder (illustration B. arrow 3) are fitted.
Installation position:
Chamfer (arrow 1) faces reverse gear
Shallow shoulder (arrow -2-) faces 5th gear
Deep shoulder (arrow 3) faces reverse gear
Fig. 24 Allocation of locking collar to reverse gear wheel
Fig. 25 Pressure plate identification
Dimension "a"
For aluminum transmissions 14.8 mm or 15.3 mm
For magnesium transmissions 10.7 mm
Fig. 26 Disc identification
Dimension "a"
For aluminum transmissions 7 mm
For magnesium transmissions 11 mm
Reinforcement measures in area of 4th and 5th gear wheel, from transmission build date 17.08.8
The following components have been changed:
1. Pinion shaft
Identification see Fig. 1
2. 4th gear wheel
Identification see Fig. 2
3. Securing clip
Identification see Fig. 2
4. Needle roller bearing
Identification see Fig. 3
5. 5th gear wheel
Identification see Fig. 3
Fig. 1 Pinion shaft identification
Fig. 2 Securing clips and 4th gear wheel identification
Fig. 3 Needle roller bearing and 5th gear wheel identification
- Allocate components according to parts
Reverse gear wheel, removing and installing
1. Circlip
2. Support plate
3. Reverse gear wheel
- Different versions, allocation
4. Needle roller bearing
5. Thrust washer
6. Transmission - cover
- With reverse gear shaft (arrow)
- To remove the reverse gear it is not necessary to remove the reverse gear shaft.
- The reverse gear shaft is not offered as a replacement part.
7. Torx screw
- Serves as an additional method of securing the reverse gear shaft
- Screw made from different materials for aluminum and magnesium transmissions
- Allocation
- For aluminum transmissions
- 35 Nm
- For magnesium transmissions
- 25 Nm