Gear Carrier, Servicing

Gear carrier, servicing





Special tools equipment
^ VW 408A Press tool
^ 10-15 Guide pin
^ 30-504 Thrust pad
^ VAG 1331 Torque wrench
^ 1 - Kukko 21/2 Internal puller
^ 4 - Kukko 22/1 Counter-support





1. Gear carrier
^ When replacing, redetermine shim S4
2. Small tapered roller bearing outer race of pinion shaft
^ Driving out; Refer to Fig. 15
^ Pressing in; Refer to Fig. 16
^ When replacing, redetermine shim S4
3. Shim S4
^ Refer to Adjustment overview
4. Cylindrical roller bearing for input shaft
^ Pressing out; Refer to Fig 5
^ Pressing in
^ Measuring pressing depth
5. Ball sleeves
^ Qty 4
^ Always replace for selector rods: Driving in and out - Fig.1
^ For reverse gear yoke: Pulling out; Refer to Fig 3; Driving in - Fig 4
6. Bolt, 35 Nm
^ For relay lever
7. Dowel pin 7 x 28
^ Drive out and in with drift
8. Reverse gear wheel
^ For reverse gear
9. Reverse gear synchro-ring
10. Spring
^ Installed position: hook end with one bend in notch in synchro-ring. Twist end with two bends counter-clockwise and hook in perforation in gear carrier.
11. Reverse gear wheel axle
12. Retaining plate
13. Spring clip
14. Bolt, 25 Nm
^ Self-locking
^ Always replace
15. Selector fork for reverse gear
16. Yoke, reverse gear Pulling out ball sleeve - Driving in ball sleeve -
17. Selector rod for 5th and 6th gear
^ Replace only complete with yoke





Fig. 1 Driving selector rod ball sleeves out and in

Set ball sleeve in with side having lettering (thicker wall) facing drift.
Pressing depth a = 2.5 mm





Fig. 2 Checking synchro-ring for wear
- Press synchro-ring onto reverse gear wheel cone and measure gap "a" with feeler gauge.
Installed dimension, new: 0.75 2.3 mm
Wear limit: 0.2 mm





Fig. 3 Pulling reverse gear ball sleeve out of yoke
A - Counter support, e. g. Kukko 22/1
B - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2





Fig. 4 Driving ball sleeve flush into reverse gear yoke
Set ball sleeve in with side having lettering (thicker wall) facing drift.





Fig. 5 Pressing input shaft cylindrical roller bearing out of gear carrier





Fig. 6 Pressing input shaft cylindrical roller bearing into gear carrier

- Measure pressing depth - Fig.7.





Fig. 7 Measuring pressing depth of input shaft cylindrical roller bearing
- Pressing depth a = 7 mm