Output Shaft, 1ST-4TH Gear, Disassembling and Assembling
Output shaft, 1st-4th gear, disassembling and assembling
Special tools and equipment
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 412 Press tool
^ VW 415bA Tube
Special tools and equipment
^ VW 309 Holding plate
^ VW 313 Support clamp
^ VW 353 Transmission support
^ VW 431 Press piece
^ VW 433 Press piece
^ VW 454 Press piece
Special tools and equipment
^ VW 512 Press disk
^ VW 516Tube
^ VW 519 Tube
^ VW 771 Multi-purpose tool
^ VW 801 Holding plate
^ 40-105 Thrust plate
Special tools and equipment
^ 40-20 Press tool
^ 40-21 Press tool
^ 2050 Thrust piece
^ 3161 Extension
^ 3235 Press
^ V.A.G. 1582 Tapered roller bearing puller
Special tools and equipment required
^ V.A.G. 1582/7 Grip
^ 1-Kukko 21/7 Internal puller
^ 1-Internal puller Kukko 21/8
^ 2-Kukko18/2 Puller
^ 3-Kukko17/2 Separating device
^ 4-Kukko 22/2 Counter support
Note:
^ When installing new gears or a new output shaft consult technical data, Refer to Manual Transmission/Transaxle, Application ID
^ If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment, Refer to Output Shaft For 1ST-4TH Gears, Adjusting
1- Clutch housing
2- Oil deflector ring
3- Dished washer
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
4- Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 3
^ Pressing in, Refer to Fig. 4
5- Tapered roller bearing inner race
^ Pressing off, Refer to Fig 8
^ Pressing on, Refer to Fig 9
6- Output shaft
7- Needle roller bearing
^ For 2nd gear
8- 2nd gear
9- Synchro-ring
^ (Inner ring for 2nd gear)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 12
10- 2nd gear outer ring
^ Insert in the synchro-ring (item -9-)
^ Replace if scored
^ Installation position, Refer to Fig. 12
11- 2nd gear synchro-ring
^ Checking for wear, Refer to Fig. 11
^ Installation position - Fig. 12
12- 1st and 2nd gear locking collar with synchro-hub
^ Pull off over bearing support after removing securing clip (item 13)
^ Disassembling, Refer to Fig. 13
^ Assembling locking collar/synchro hub, Refer to Fig. 13 and - Fig. 14
^ Installation position, Refer to Fig. 15
^ Pressing on, Refer to Fig. 16
13- Securing clip
14- 1st gear synchro-ring
^ Checking for wear, Refer to Fig. 11
^ Assemble so that recesses locate in locking collar (item -12 -) locking pieces
15 -1st gear outer ring
^ Insert in the synchro-ring (item -11-), installation position , Refer to Fig. 17
^ Replace if scored
16- Synchro-ring
^ (1st gear inner ring)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 18
17- Needle roller bearing
^ For1st gear
18- 1st selector gear
^ Installation position, Refer to Fig. 19
19- Thrust washer
^ For 1st and 4th gear
^ Insert lugs on thrust washer in holes on output shaft
20- Shim
^ Holds thrust washer (-item 19 -) in position on output shaft
21- Needle roller bearing
^ For 4th gear
22- Selector gear for 4th gear
23- 4th gear synchro-ring
^ Checking for wear, Refer to Fig. 22
24- Locking collar with 3rd and 4th gear synchro-hub
^ Pull off by pulling off 4th gear wheel after removing the circlip (item -25-)
^ Disassembling, Refer to Fig. 13
^ Installation position locking
^ collar/synchrohub, Refer to Fig. 20
^ Assembling locking collar/synchro hub, Refer to Fig. 13 and Fig. 14
^ Pressing on, Refer to Fig. 21
25- Securing clip
26- 3rd gear synchro-ring
^ Checking for wear, Refer to Fig. 11
27- Outer ring for 3rd gear
^ Insert in the synchro-ring (item - 26 -), installation position, Refer to Fig. 17
^ Replace if scored
28- Synchro-ring
^ (3rd gear inner ring)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 18
29- Needle roller bearing
^ For 3rd gear
3- Selector gear for 3rd gear
^ Installation position, Refer to Fig. 19
31- Tapered roller bearing inner race
^ Pulling off, Refer to Fig.5
^ Pressing on, Refer to Fig. 23
32- Securing clip
^ Redetermine thickness if tapered roller bearing (-item 6 -) or output shaft (-item 31 -) are replaced, Refer to Fig. 24
33- Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 25
^ Pressing in, Refer to Fig. 26
34- Shim
35- Transmission housing
Fig. 1 Pulling dished washer -A- out of output shaft
Fig. 2 Pressing dished washer -A- into output shaft onto stop
Fig. 3 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
A - Internal puller 56 to 70 mm, e.g. Kukko 21/8
Fig. 4 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press tool 40-20 directly below bearing mounting.
Fig. 5 Pulling off tapered roller bearing inner race
^ Before mounting puller, position press piece VW 431 in output shaft and set thrust plate 40-105 on it.
Fig. 6 Pulling off 3rd and 4th gear synchro-hub/locking collar over 4th gear wheel
^ First remove securing clip.
A- Puller, e.g. Kukko 18/2
B - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 7 Pressing off 1st and 2nd gear locking collar and synchrohub
^ After removing securing ring press 2nd selector gear and locking collar/synchro-hub off together.
Fig. 8 Pulling off tapered roller bearing inner race
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 9 Pressing on tapered roller bearing inner race
Fig. 10 Checking inner ring for 1st, 2nd and 3 gear for wear
^ Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.
Fig. 11 Checking 1st, 2nd and 3rd gear synchro-rings for wear
^ Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.
Fig. 12 Installation position of outer ring, inner ring and 2nd gear synchro ring
^ Place inner ring -A- on 2nd gear wheel.
^ Angled lugs (arrow -1-) point toward outer ring -B-.
^ Fit outer ring -B-.
Lugs (arrow -2-) engage in gear wheel recesses (arrow 3).
^ Fit synchro-ring -C-.
The recesses (arrow -4-) engage in lugs (arrow -1-) of inner ring -A-.
Fig. 13 Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
1- Spring
2- Locking piece
3- Locking collar
4- Synchro-hub
^ Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.
Fig. 14 Assembling 1st and 2nd gear locking collar/synchro-hub
The locking collar has been pushed over the synchro-hub.
^ Insert locking pieces and install springs 120° offset. Angled end of spring must locate in hollow locking piece.
Fig. 15 Installation position of 1st and 2nd gear locking collar/synchro-hub
Identification groove (arrow -1-) and narrow collar (arrow -2-) of synchrohub point toward 1st gear.
Fig. 16 Pressing on 1st and 2nd gear locking collar/synchro-hub
Fig. 17 Installation position for 1st or 3rd gear outer ring
Lugs (arrows) face toward synchro-hub/locking collar -A
Fig. 18 Installation position synchro-ring (inner ring) -A-
The lugs (arrows -1-) engage in the recesses (arrow 2) in the synchro-ring -B-.
Fig. 19 Installation position 1st and 3rd gear wheel
The higher shoulder -A- faces toward 2nd or 4th gear -B-. The recesses in the shoulder (arrows) engage in the lugs of the outer ring (arrow 17)
Fig. 20 Installation position 3rd and 4th gear locking collar/synchro-hub
The wider shoulder of the synchro-hub (arrow) faces toward 3rd gear.
Fig. 21 Pressing on 3rd and 4th gear synchro-hub with locking collar
Fig. 22 Checking synchro-ring for wear
^ Press synchro-ring onto gear cone and measure gap "a" with feeler gauge.
Fig. 23 Pressing on tapered roller bearing inner race
Fig. 24 Determining thickness of circlip
^ Determine thickest circlip which will still fit and install it.
The following securing clips are available:
Fig. 25 Pulling tapered roller bearing outer race out from transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Fig. 26 Pressing tapered roller bearing outer race into transmission housing
^ Fit shim under outer race.
^ Support transmission housing with press piece 2050 directly below bearing support.