Drive Pinion As of Transmission Manufacture Date 23 06 3, Disassembling and Assembling
Drive pinion as of transmission manufacture date 23 06 3, disassembling and assembling, 012/01W, 5 SPD. M/T
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 VW 415 A
Special tools, testers and auxiliary items required:
^ Pulling device for crankshaft oil seal VW 204 B
^ Tube 28mm Dia. 1 00mm VW 421
^ Thrust Tube VW 455
^ Sleeve VW 519
^ Slide Hammer-Complete Set VW 771
^ Sleeve 2010
Special tools, testers and auxiliary items required:
^ Thrust Pad 3005
^ Press Support 3118
^ Bushing Puller 3128
^ Assembly Tool 3301
^ - 1 - Internal extractor Kukko 21/4
^ - 3 - Separating tool Kukko 17/2
Note:
^ As of transmission manufacture date 23 06 3 new triple synchronization for 1st gear and dual synchronization for 2nd gear as well as synchronizer rings with larger friction cone and smaller toothing for 5th gear and reverse gear. Drive gears, operating sleeves and synchronizers are adapted accordingly and cannot be installed together with synchronizing parts of the previous construction version.
^ When installing new gears or gear set, observe technical data.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing 1)
2. Adjustment shim "S3"
3. Large tapered roller bearing outer race
^ Pulling out
^ Pressing in
4. Drive pinion
^ Matched to ring gear, always replace together as a set
5. Large tapered roller bearing inner race
^ Damaged when removed
^ Replace
^ Pressing off
^ Pressing on
6. Circlip
^ Identification
^ Installed position - item 1 -
^ Re-determining thickness when replacing tapered roller bearing
7. Needle bearing for 1st gear
8. 1st gear
9. Inner race for 1st gear
^ Installed position
^ Checking for wear
^ Replace if scored or show signs of wear
10. Intermediate ring for 1st gear
^ Installed position
^ Checking for wear
11. Synchronizer ring for 1st gear
^ Installed position
^ Checking for wear
^ Replace if scored or show signs of wear
12. Operating sleeve for 1st and 2nd gear
^ Mark installation position
^ Assembling operating sleeve/synchronizer hub
13. Thrust piece
^ Install thrust pieces (3 pcs.)
14. Synchronizer hub for 1st and 2nd gears
^ Pressing off
^ Pressing on
^ Assembling operating sleeve/synchronizer hub
15. Circlip
^ Identification
^ Installed position - item 2 -.
^ Re-determining thickness when replacing synchronizer body
16. Needle bearing 2nd gear
17. Synchronizer ring for 2nd gear
^ Installed position
^ Checking for wear
^ Replace if scored or show signs of wear
18. Intermediate ring for 2nd gear
^ Installed position
^ Checking for wear
19. Inner race for 2nd gear
^ Installed position
^ Checking for wear
^ Replace if scored or show signs of wear
20. 2nd gear
21. Circlip
^ Identification
^ Installed position - item 3 -
22. 3rd gear
^ Pressing off
^ Groove faces 4th gear
^ Pressing on
23. Circlip Identification Installed position - item 4 -
^ If 3rd gear is replaced, re-determine thickness of circlip
24. 4th gear
^ Pressing off
^ Shoulder faces 3rd gear
^ Pressing on
25. Circlip
^ Identification
^ Installed position - item 5 -
^ If 4th gear is replaced, re-determine thickness of circlip
26. Needle bearing
27. 51th gear
^ Modifying characteristic
28. Spring
^ Modifying characteristic
^ Inserting in 5th gear
^ Application of spring to gear Electronic Parts Catalog (ETKA)
29. Synchronizer ring for 5th gear
^ Modifying characteristic
^ Checking for wear
30. Circlip
^ Identification
^ Installed position - item 6 -
31. Synchronizer hub for 51th and reverse gear
^ Modifying characteristic
^ Pressing off
^ Pressing on
32. Circlip
^ Identification
^ Installed position - item 5 -
^ Re-determining thickness when replacing synchronizer body
33. Needle bearing
^ For reverse gear
34. Operating sleeve for 5th and reverse gear
^ Modifying characteristic
^ Installed position: Groove faces 5th gear
35. Synchronizer ring reverse gear
^ Modifying characteristic
^ Checking for wear
36. Spring
^ Modifying characteristic
^ Inserting in reverse gear
37. Gear wheel for reverse gear
^ Modifying characteristic
38. Small tapered roller bearing inner race
^ Pressing off
^ Pressing on
39. Socket
^ Secures small tapered roller bearing outer race
^ Pulling out
^ Does not need to be reinstalled after small tapered roller bearing was replaced
40. Small tapered roller bearing outer race
^ Pulling out
^ Pressing in
41. Adjustment shim "S4"
42. Thrust plate
^ Various thicknesses for transmissions made out of aluminum and magnesium
43. Rubber washer
^ Compensated length variations
^ When removing, screw in sheet metal screw in center and remove washer at sheet metal screw.
^ Various thicknesses for transmissions made out of aluminum and magnesium
44. Transmission cover
^ Made out of aluminum, may only be installed with transmission housing made out of aluminum
^ Made out of magnesium, may only be installed with transmission housing made out of magnesium
^ Note identification
^ Coat sealing surfaces with a thin layer of sealant AMV 188 001 02
Modified synchronization 5th and reverse gear as of transmission manufacture date 23 06 3
Note:
^ Parts of previous version up to transmission manufacture date 22 06 3 and parts of new version transmission manufacture date 23 06 3 must not be installed together.
The following components were modified:
1. 5th gear
2. Synchronizer spring
3. Synchronizer ring for 5th gear
4. Synchronizer hub for 5th and reverse gear
5. Operating sleeve for 5th and reverse gear
6. Synchronizer ring for reverse gear
7. Synchronizer spring
8. Gear wheel for reverse gear
Scope of modifications:
^ Smaller toothing - arrows A -
^ Synchronizer rings with larger friction cone - arrows B -
Pulling off securing bushing for small tapered roller bearing outer race
A - Internal puller 12 to 16 mm, e.g. Kukko 21/1
Pulling off outer race of small tapered roller bearing
^ Install special tool VW 771/40 into thrust plate.
^ Install Slide Hammer-Complete Set VW 771 and pull out outer race over thrust plate.
Pressing in outer race for small tapered roller bearing
Pulling out double tapered roller bearing outer race
^ Place pressure piece from Bushing Puller 3128 under outer race.
^ Install threaded spindle and thrust bearing of Assembly Tool 3301 with Thrust Plate VW 401 onto transmission housing.
When the bolt is tightened, the outer race will be pulled out of the housing.
Pressing in double tapered roller bearing outer race
The smaller diameter of the arbor VW 204 B faces outer race.
Pressing off tapered roller bearing inner race
^ Press off inner race together with reverse gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Press off synchronizer hub for 5th and reverse gear
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 5th gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off 4th gear
^ Remove circlip before pressing off.
Pressing off 3rd gear
^ Remove circlip before pressing off.
Note:
^ When pressing off make sure that only teeth of gear wheel - arrows - contact separating tool - A - but not shift teeth. Otherwise shift teeth will be damaged.
^ Press off 3rd gear with 2nd gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off synchronizer hub for 1st and 2nd gears
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 1st gear.
Pressing off double tapered roller bearing inner race
^ Remove circlip before pressing off.
^ Outer race - A - must be installed to press off inner race.
Pressing on double tapered roller bearing inner race
Determining circlip
^ Determine thickest circlip which can still just be installed - and insert.
^ Circlips for synchronizer hubs and individual gears should be determined as for tapered roller bearing as shown. Circlips available and part numbers Electronic Parts Catalog (ETKA).
Installed position of circlips
^ Circlips for synchronizer hubs, needle bearings and individual gears should also be determined as shown in illustration
Circlip - 1 - secures inner race of tapered roller bearing.
^ Circlip - 2 - secures the synchronizer hub for 1st and 2nd gear.
Distinguishing characteristic: blue color
^ Circlip - 3 - secures needle bearing for 2nd gear.
Distinguishing characteristic: blue color
Circlip - 4 - secures 3rd gear.
Circlip - 5 - secures 4th gear. secures needle bearing for 5th gear.
Circlip - 6 - secures needle bearing for 5th gear.
Allocate circlip via Electronic Parts Catalog (ETKA).
Distinguishing characteristic: brown color
Circlip - 7 - secures synchronizer hub for 5th and reverse gear.
Distinguishing characteristic: blue color
Determine circlips according to table.
Installed position synchronizer rings for 1st and 2nd gear
Note:
^ If the components are not going to be replaced, be sure that they are re-assigned to the same gear.
^ Place inner race - 2 - on gear - 1 -.
^ Place intermediate ring - 3 -. Lug - B - must be inserted into recess - A -.
^ Synchronizer ring - 4 - is placed. Guide lugs - C - through recess - arrow
Checking inner race of 1st gear for wear
^ Check outer friction area - arrow - for scores or signs of wear, replace if necessary.
^ Press inner race onto cone of gear wheel and measure gap dimension "a" using a feeler gauge.
Checking synchronizer ring for 1st and 2nd gears for wear
^ Check synchronizer ring at inner friction area for scores or signs of wear, replace if necessary.
^ Press inner race, intermediate ring and synchronizer ring onto cone of gear wheel and measure gap dimension "a" using a feeler gauge.
Press on synchronizer hub for 1st and 2nd gears
^ Installed position:
Higher inner collar faces 2nd gear
Assembly of operating sleeve/synchronizers for 1st and 2nd gear
^ Insert pressure pieces - arrows A - into mounted synchronizer hub - 1 -.
^ Place operating sleeve - 2 - on synchronizer hub so that wide grooves of operating sleeve and synchronizer hub - arrow B - line up.
Pressing on 3rd gear
^ Installed position:
High inner collar and groove on gear faces 4th gear.
Pressing on 4th gear
^ Installed position:
High inner collar and groove on gear faces 3rd gear.
Inserting spring into gear
The bent end of spring - arrow - must be hooked into hole of shift gear.
Checking synchronizer ring for 5th and reverse gears for wear
^ Press synchronizer ring into operating sleeve and measure gap dimension - a - using a feeler gauge at positions - B - and - C -.
^ Add measured values and divide total by three to calculate average.
Determined value must not be more than 0.45 mm.
Press on synchronizer hub for 5th and reverse gear
^ Installed position:
Higher inner collar faces 5th gear
Note:
^ The larger inner diameter of Sleeve 20 10 points toward synchronizer hub.
Installation position of operating sleeve for 5th and reverse gear
^ Installed position:
Groove - arrow - faces 5th gear
Pressing on tapered roller bearing inner race
Differentiation of thrust plates
Differentiation of rubber washers
