Output Shaft, 1ST-4TH Gear, Disassembling and Assembling
Output shaft, 1st-4th gear, disassembling and assembling, 02M, 5 and 6 Spd. M/T
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 415 A 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 516 Tube
- 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
- VAG 1582 Tapered roller bearing puller
- V.A.G 1582/7 Grip
Special tools and equipment required:
- 1 - Kukko 21/7 Internal puller
- 1 - Internal puller Kukko 21/8
- 2 - Kukko 18/2 Puller
- 3 - Kukko 17/2 Separating device
- 4 - Kukko 22/2 Counter support
Note:
- When installing new gears or a new output shaft consult technical data.
- If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment.
1. Clutch housing
2. Oil deflector ring
3. Dished washer
^ Pulling out go to Fig. 1
^ Pressing in go to Fig. 2
4. Outer race/tapered roller bearing
^ Pulling out go to Fig. 3
^ Pressing in go to Fig. 4
5. Tapered roller bearing inner race
^ Pressing off go to Fig. 8
^ Pressing on go to Fig. 9
6. Output shaft
^ For 1st-4th gear
^ Adjusting
7. Needle roller bearing
^ For 2nd gear
8. 2nd gear
9. Synchro-ring
^ (Inner ring for 2nd gear)
^ Checking for wear go to Fig. 10
^ Check lugs for scoring
^ Installed position go to Fig. 12
10. 2nd gear outer ring
^ Insert in the synchro-ring (item -9-)
^ Replace if scored
^ Installed position go to Fig. 12
11. 2nd gear synchro-ring
^ Checking for wear go to Fig. 11
^ Installed position go to Fig. 12
12. 1st and 2nd gear locking collar with synchro-hub
^ Pull off over bearing support after removing securing clip (item -13-) go to Fig. 7
^ Disassembling go to Fig. 13
^ Assembling locking collar/synchro hub go to Fig. 13 and Fig. 14
^ Installed position go to Fig. 15
^ Pressing on go to Fig. 16
13. Securing clip
14. 1st gear synchro-ring
^ Checking for wear go to Fig. 11
^ Assemble so that recesses locate in locking collar (item -12-) locking pieces
15. 1st gear outer ring
^ Insert in synchro-ring (item -14-)
^ Installed position go to Fig. 17
^ Replace if scored
16. Synchro-ring
^ (1st gear inner ring)
^ Checking for wear go to Fig. 10
^ Check lugs for scoring
^ Installed position go to Fig. 18
17. Needle roller bearing
^ For 1st gear
18. 1st selector gear
^ Installed position go 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 go to Fig. 22
24. Locking collar with 3rd and 4th gear synchro-hub
^ Pull off by pulling off 4th gear wheel after removing circlip (item -25-) go to Fig. 6
^ Disassembling go to Fig. 13
^ Installed position locking collar/synchro-hub go to Fig. 20
^ Assembling locking collar/synchro hub go to Fig. 13 and Fig. 14
^ Pressing on go to Fig. 21
25. Securing clip
26. 3rd gear synchro-ring
^ Checking for wear go to Fig. 11
27. Outer ring for 3rd gear
^ Insert in synchro-ring (item -26-)
^ Installed position go to Fig. 17
^ Replace if scored
28. Synchro-ring
^ (3rd gear inner ring)
^ Checking for wear go to Fig. 10
^ Check lugs for scoring
^ Installed position go to Fig. 18
29. Needle roller bearing
^ For 3rd gear
30. Selector gear for 3rd gear
^ Installed position go to Fig. 19
31. Tapered roller bearing inner race
^ Pulling off go to Fig. 5
^ Pressing on go to Fig. 23
32. Securing clip
^ Redetermine thickness if tapered roller bearing (item -31-) or output shaft (item -6-) are replaced go to Fig. 24
33. Outer race/tapered roller bearing
^ Pulling out go to Fig. 25
^ Pressing in go to Fig. 26
34. Shim
^ Determining thickness
35. Transmission housing
Fig. 1 Pulling dished washer -A- out of output shaft
Fig. 2 Pressing dished washer 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
- Remove securing clip.
- 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 synchro-hub
- 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 3rd 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 Installed 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-.
- 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.
- 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 Installed position of 1st and 2nd gear locking collar/synchro-hub
- Identification groove (arrow -1-) and narrow collar (arrow -2-) of synchro-hub point toward 1st gear.
Fig. 16 Pressing on 1st and 2nd gear locking collar/synchro-hub
- Install securing clip.
Fig. 17 Installed position of 1st or 3rd gear outer ring
- Lugs (arrows) face toward synchro-hub/locking collar -A-.
Fig. 18 Installed position for synchro-ring (inner ring) -A-
- The lugs (arrows -1-) engage in the recesses (arrow 2) in the synchro-ring -B-.
Fig. 19 Installed position of 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 ( go to arrows Fig. 17)
Fig. 20 Installed position of 3rd and 4th gear locking collar/synchro-hub
The wider shoulder of the synchro-hub (arrow) faces 3rd gear.
Fig. 21 Pressing on 3rd and 4th gear synchro-hub with locking collar
- Install securing clip.
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
- Determine securing clip go to Fig. 24 and install it.
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.