Output Shaft, Disassembling and Assembling
Output shaft, disassembling and assembling, 02J, 5 Spd. M/T
Special tools and equipment:
- VW 407 Press tool
- VW 412 Press tool
- VW 512 Press disk
- V.A.G 1582 Puller
- V.A.G 1582/4 Grip piece
- V.A.G 1582/5 Grip piece
Special tools and equipment:
- VW 402 Press plate
- 32-111 Thrust piece
- VW 408 A Press tool
- VW 409 Press tool
- VW 457 Support rails
- VW 519 Tube
Special tools and equipment:
- VW 429 Thrust ring
- VW 415 A Tube
- VW 447 H Press plate
- VW 454 Press piece
- VW 455 Fitting sleeve
- 41-501 Drift sleeve
Special tools and equipment
1 - Kukko 21/6 Internal extractor
4 - Kukko 22/2 Retainer
Note: The output shaft is disassembled as follows:
- Position separating device under 2nd gear wheel (item 19) and press off as described in Fig. 5.
- Remove circlip (item 15).
- Position two-arm puller under bearing support (item 9) and pull off locking collar with 1st and 2nd gear synchro-hub described in Fig. 6.
- When installing new gear wheels or a new output shaft consult technical data.
- Both tapered roller bearings must be replaced as a set.
1. Hex nut, 25 Nm plus an additional 1/4 turn 90°
^ 4 nuts for bearing support
2. Clutch housing
3. Shim
^ For output shaft
^ Adjustment overview
4. Small tapered roller bearing outer race
^ Removing go to Fig. 1
^ Pressing in go to Fig. 2
5. Small tapered roller bearing inner race
^ Pulling off go to Fig. 3
^ Pressing on go to Fig. 4
6. Output shaft
^ Is paired with final drive gear wheel, always replace together as a set
^ Adjusting
7. Large tapered roller bearing inner race
^ Pulling off go to Fig. 7
^ Pressing on go to Fig. 8
8. Sealing ring
^ Place sealing rings (Qty. 4) on bearing support bolts
9. Bearing support
^ With large tapered roller bearing outer race and bolts
^ Only change outer race with large tapered roller bearing and bearing support
10. Thrust washer
^ Shoulder on thrust washer faces tapered roller bearing
11. 1st gear wheel
^ From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed
12. Needle roller bearing
^ For 1st gear
13. 1st gear synchro-ring
^ Checking for wear go to Fig. 9
^ Identification go to Fig. 14
^ From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed
14. 1st and 2nd gear locking collar with synchro-hub
^ Pull off with bearing support after removing circlip (item 15) go to Fig. 6
^ Disassembling go to Fig. 10
^ Assembling locking collar/synchro hub go to Fig. 10 and Fig. 11
^ Installation position go to Fig. 12
^ Pressing on go to Fig. 13
^ From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed
15. Securing clip
16. 2nd gear synchro-ring
^ Identification go to Fig. 14
^ Checking for wear go to Fig. 16
^ Assemble so that recesses locate in locking collar (item 14) locking pieces
^ From transmission manufacture date May 02 00 the synchronizer for 1st gear was changed
17. Outer ring
^ Insert in synchro-ring (item 16). Installation position go to Fig. 17
^ Replace if scored or worn
18. Synchro-ring
^ (Inner ring)
^ Checking for wear go to Fig. 18
^ Check lugs for scoring
^ Installation position go to Fig. 19
19. 2nd gear wheel
^ Installation position go to Fig. 20
20. Needle roller bearing
^ For 2nd gear
21. Thrust washer
22. Sleeve for 3rd gear needle roller bearing
^ Pressing off with 2nd gear wheel go to Fig. 5
^ Pressing on go to Fig. 21
23. Needle roller bearing
^ For 3rd gear
24. 3rd gear wheel
25. 3rd gear synchro-ring
^ Checking for wear go to Fig. 9
26. Locking collar with 3rd and 4th gear synchro-hub
^ Press off with 2nd gear wheel (item 19) and 3rd gear wheel (item 24) go to Fig. 5
^ Disassembling go to Fig. 22
^ Installation position locking collar/synchro-hub go to Fig. 24
^ Assembling locking collar/synchro-hub go to Fig. 22 and Fig. 23
^ Pressing on go to Fig. 25
27. Sleeve
^ For needle roller bearing
^ Press off with locking collar and 3rd and 4th gear synchro-hub (item 26) go to Fig. 5
^ Pressing on go to Fig. 26
28. Needle roller bearing
^ For 4th gear
29. 4th gear synchro-ring
^ Checking for wear go to Fig. 9
30. 4th gear wheel
31. Thrust washer
32. Needle roller bearing
^ For output shaft
^ Removing and installing
33. Transmission housing
34. Sleeve
^ For output shaft needle roller bearing
^ Pressing off go to Fig. 5
^ Pressing on go to Fig. 27
35. 5th gear wheel
^ Removing and installing
36. Saucer spring washer
^ Installation position
37. Torx socket head bolt M10, 80 Nm
^ Installed portion on bolt head holds saucer spring washer in position
Fig. 1 Pulling out small tapered roller bearing outer race
A - Internal extractor 37... 46 mm, e.g. Kukko 21/6
B - Counter support, e.g. Kukko 22/2
Fig. 2 Pressing in small tapered roller bearing outer race
Fig. 3 Pulling off small tapered roller bearing inner race
A - Vice clamps/vice
- Install gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.
Fig. 4 Pressing on small tapered roller bearing inner race
Fig. 5 Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with transmission housing needle roller bearing sleeve
A - Separating device 22... 115 mm, e.g. Kukko 17/2
B - Hex bolt 17 mm AF - M10 x 20
Note: Support separating appliance so that the 1st and 2nd gear locking collar is not pulled off at the same time.
Fig. 6 Pulling off locking collar with synchro-hub and bearing support
- First remove the circlip -arrow-.
Fig. 7 Pulling off large tapered roller bearing inner race
A - Vice clamps
- Before installing puller insert a M 10 x 20 hex bolt in output shaft drilling.
Fig. 8 Pressing on large tapered roller bearing inner race
A - Thrust washer
- Install thrust washer before pressing on inner race. Shoulder faces inner race.
Fig. 9 Checking synchro-ring for wear
- Press synchro-ring onto gear wheel cone and measure gap "a" with feeler gauge.
Fig. 10 Disassembling and assembling 1st and 2nd gear locking collar and synchro-hub
1 - Spring
2 - Locking collar
3 - Synchro-hub
4 - Locking piece
Slide locking collar over synchro-hub.
- The wide shoulder of the synchro-hub (arrow -A-) and the outer splines of the locking collar (arrow -B-) face opposite directions after assembly. Recesses for locking pieces on synchro-hub and locking collar must align.
Fig. 11 Assembling 1st and 2nd gear locking collar/synchro-hub
- Locking collar is pushed over synchro-hub.
- Insert locking pieces and install springs 120° off-set. The angled end of spring must locate in hollow locking piece.
Fig. 12 Installation position 1st and 2nd gear locking collar/synchro-hub
- The locking collar splines (arrow -1-) point to splines for 3rd/4th gear synchro-hub -A-.
- The wide shoulder of the synchro-hub (arrow -2-) then faces to 1st gear -B-.
Fig. 13 Pressing on 1st and 2nd gear locking collar/synchro-hub
Note: Before pressing on, place 1st gear synchro-ring on 1st gear wheel.
Fig. 14 Identifying 1st and 2nd gear synchro-rings
- 1st gear synchro-ring: 3 x 1/2 ground-down half teeth (arrow)
- 2nd gear synchro-ring: 3 x 1/2 ground down half teeth (arrow) or 2 ground-down half teeth
- Only the version with 2 x 1/2 ground-down half teeth is available as a spare part for the 2nd gear synchro-ring.
Fig. 15 Distinguishing 1st and 2nd gear synchro-rings
1st gear synchro-ring - no recesses
2nd gear synchro-ring - three recesses (arrows)
Fig. 16 Checking 2nd gear synchro-ring for wear
- Press synchro-ring, outer-ring and inner-ring onto gear wheel cone and measure gap "a" with feeler gauge.
Fig. 17 Installation position outer-ring
The lugs (arrows) face to 1st gear -A-.
Fig. 18 Checking inner ring for wears
- Press inner ring onto 2nd gear wheel cone and measure gap "a" with a feeler gauge.
Fig. 19 Installation position synchro-ring (inner-ring) -A-
The lugs (arrow -1-) locate in the recesses (arrow -2-) in the synchro-ring -B-.
Fig. 20 Installation position 2nd gear wheel
The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate with the lugs of the outer-ring (arrow go to Fig. 17)
Fig. 21 Pressing on needle roller bearing sleeve for 3rd gear
Fig. 22 Disassembling and assembling 3rd and 4th 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. 23 Assembling 3rd and 4th gear locking collar/synchro-hub
- The locking collar has been pushed over the synchro-hub.
- If the locking pieces are inner hollow
- Insert locking pieces and install springs 120° off-set. Angled end of spring must locate in hollow locking piece.
- If the locking pieces are not inner hollow
- Insert locking pieces and install springs 120° off-set. The spring must locate with the angled ends of the locking pieces.
Fig. 24 Installation position 3rd and 4th gear locking collar/synchro-hub
- Chamfer (arrow) faces to 4th gear.
Fig. 25 Pressing on 3rd and 4th gear synchro-hub with locking collar
Fig. 26 Pressing on sleeve for 4th gear needle roller bearing
Fig. 27 Pressing on sleeve for output shaft needle roller bearing