Pinion Shaft and Hollow Shaft, Disassembling and Assembling

Pinion shaft and hollow shaft, disassembling and assembling





Special tools and equipment
^ VW 295 Drift
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 411 Press tool
^ VW 412 Press tool





Special tools and equipment
^ VW 415A Tube
^ VW 457 Support rails
^ VW 771 Multipurpose tool
^ 2003/3 Installing ring
^ 3013 Drift
^ 3062 Press disk





Special tools and equipment
^ 3118 Tube
^ 3138 Driver
^ VAG 1416 Hot air blower
^ 1 - Kukko 21/1 Internal puller
^ 3 - Kukko 17/2 Separating device





Note:
^ When installing new gear wheels or the crown wheel and pinion shaft consult technical data.
^ Components marked with [1] indicate adjustment work is required if these components are replaced; Refer to Adjustment overview.

1. Transmission housing [1]
2. Shim S3
3. Large tapered roller bearing outer race [1]
4. Pinion shaft [1]
^ Is mated with ring gear. Always replace together as a set
5. Needle roller bearing
6. Large tapered roller bearing inner race[1]
7. Circlip
^ Redetermine thickness
8. Lip ring
9. Tapered roller bearings
10. Support ring
11. Corrugated spring
12. Needle roller bearing
^ For pinion shaft/hollow shaft
^ Lubricate with gear oil before installing
13. Hollow shaft [1]
^ With wheels for 3rd and 4th gears
14. Needle roller bearing
^ For 2nd gear
^ Lubricate with gear oil before installing
15. 2nd gear wheel
^ Pressing off; Refer to Fig. 12
^ Before installing, set spring on shaft and push needle roller bearing onto hollow shaft
16. 2nd gear synchro-ring
^ Coated with Molybdenum
^ Checking for wear; Refer to Fig. 2
17. 1st and 2nd gear synchronizing hub
^ Pressing off; Refer to Fig. 12
^ Pressing on; Refer to Fig. 13
^ Installed position: hub flush with edge of wheel facing 2nd gear wheel
18. Securing clip
^ Removing and installing; Refer to Fig. 11
^ Redetermine thickness
19. Washer
^ For 1st gear sliding wheel needle roller bearing
^ Removing and installing; Refer to Fig. 11
20. 1st and 2nd gear locking collar
21. 1st gear synchro-ring
^ Checking for wear; Refer to Fig. 2
22. Needle roller bearing
23. 1st selector gear
^ Set spring on shaft before installing; Refer to Fig. 1
^ Check axial play after pressing on item - 24
24. Small tapered roller bearing inner race[1]
^ Pressing off; Refer to Fig 9
^ Pressing on; Refer to Fig. 10
^ Low friction bearing; do not lubricate for checking friction measurement
25. Small tapered roller bearing outer race[1]
Pulling out; Refer to Fig. 15
^ Pressing in; Refer to Fig. 16
26. Shim S4
^ Refer to Adjustment overview
27. Gear carrier[1]
28. 6th gear wheel
29. Spacer sleeve
30. Washer
31. 5th gear wheel
32. Circlip
33. End cover

Fig. 1 Pulling out large tapered roller bearing outer race





Stepped side of press disk 3062 contacts outer race.





Fig. 2 Heat transmission housing to insert large tapered roller bearing outer race

- Heat transmission housing with hot air blower around bearing seat for about 15 minutes to about 100°C





Fig. 3 Inserting and pressing large tapered roller bearing outer race into transmission housing

- Insert outer race in heated transmission housing and press in with workshop press until temperatures have equalized.





Fig. 4 Pulling out flanged shaft/pinion shaft needle roller bearing

A - Internal extractor 12 - 14.5 mm, e g. Kukko 21/1





Fig. 5 Driving in flanged shaft/pinion shaft needle roller bearing flush





Fig. 6 Pressing off large tapered roller bearing inner race

A - Separating device 22 - 115 mm, e g. Kukko 17/2

Note: Pressing off destroys bearing.

Fig. 7 Pressing on large tapered roller bearing inner race





- Heat inner race to about 100°C and set on shaft.
- Press on so that there is no axial play.





Fig. 8 Determining thickness of circlip
- Determine thickest circlip which will still fit and install.

Note: Determine part numbers according to Parts Supplier.





The following circlips are available:
- Install circlip.





Fig. 9 Pressing off small tapered roller bearing inner race together with 1st gear sliding wheel

Note: Do not press off together with 1st and 2nd gear synchronizing hub and 2nd gear sliding wheel.





Fig. 10 Pressing on small tapered roller bearing inner race

- Lubricate needle roller bearing.
- Install circlip, 1st gear synchronizing selector gear shim, 1st gear synchro-ring, and 1st gear selector gear with spring and needle roller bearing.
- Heat inner race to about 100°C and set on shaft.
- Press on so that there is no axial play.

Note:
^ With collar of thrust piece 3118 downward, apply pressure only to inner bearing race.
^ Arrange collar of tube VW 415A upward toward press tool VW 412.
^ After pressing, check axial play of 1st gear sliding wheel.





Fig. 11 Removing and installing circlip for synchronizing hub and shim for 1st gear sliding wheel

- To remove, first take off shim -A- and then circlip -B-.
- To install, first put circlip -B- on shaft and then shim -A-.





Fig. 12 Pressing off 2nd gear sliding wheel with 1st and 2nd gear synchronizing hub

- Remove 1st and 2nd gear locking collar and 1st gear synchro-ring.
- Remove shim and circlip for synchronizing hub.
- Press off 2nd gear sliding wheel together with 1st and 2nd gear synchronizing hub.

Note: Do not press off together with 1st gear sliding wheel and small tapered roller bearing inner race.





Fig. 13 Installing 2nd gear sliding wheel and pressing on 1st and 2nd gear synchronizing hub

- Install needle roller bearing, 2nd gear sliding wheel with spring and syncro-ring. - Lubricate needle roller bearing. - Heat synchronizing hub to about 100°C and put on shaft.
- Press on so that there is no axial play.

Note:
^ Put on tube VW 415A with collar facing synchronizing hub.
^ Arrange thrust piece 3118 with step facing press tool VW 412.





Fig. 14 Determining circlip for 1st and 2nd gear synchronizing hub

- Determine thickest circlip which will still fit and install.

Note: Determine part numbers according to parts catalog.





The following circlips are available:
- Insert circlip in synchronizing hub in direction of arrow.





Fig. 15 Driving out small tapered roller bearing outer race





Fig. 16 Pressing in small tapered roller bearing outer race
- Insert shim S4 behind bearing seat in gear carrier.
- Arrange step of thrust pad 3062 facing press tool VW 407.
- Press in small tapered roller bearing outer race.