Pinion Shaft and Hollow Shaft, Disassembling and Assembling (Up to Transmission Manufacture Date 22 06 3)
Pinion shaft and hollow shaft, disassembling and assembling (up to transmission manufacture date 22 06 3), 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 407
^ Punch VW 411
^ Punch VW 412
^ Tube VW 415 A
Special tools, testers and auxiliary items required:
^ Tube VW 416 B
^ Tube VW 418 A
^ Thrust ring VW 429
^ Thrust pad VW 447 i
^ Thrust piece VW 454
^ Tube VW 519
Special tools, testers and auxiliary items required:
^ Slide hammer VW 771
^ Sleeve 40 - 103
^ Tube 2010
^ Thrust pad 3062
^ Assembly tool 3128
^ Separating device Kukko 17/2
^ Internal puller Kukko 21/1
Note:
^ As of transmission manufacture date 23 06 3, a new synchronization for 1st and 2nd gear as well as for 5th and reverse gear has been implemented. Disassembling and assembling pinion shaft, as of transmission manufacture date 23 06 3.
^ When installing new gear wheels or gear set, note Technical Data.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing
2. Adjustment shim "S3"
3. Outer race for double tapered roller bearing
^ Pulling out
^ Pressing in
4. Pinion shaft
^ Matched to ring gear, always replace together as a set
^ Pinion shaft and ring gear, adjusting
5. Inner race for double tapered roller bearing
^ Damaged when removed
^ Replace
^ Pressing off
^ Pressing on
6. Circlip
^ Re-determining thickness when replacing double tapered roller bearing
7. Needle bearing
^ For pinion shaft in hollow shaft
^ Lubricate with grease MoS2
8. Hollow shaft')
^ Reinforcement measures as of transmission manufacture date 17 08 8
9. Needle bearing for 1st gear
10. Needle bearing for 1st gear
11. 1st gear sliding gear
12. Spring
^ Inserting in 1st gear sliding gear
13. Synchronizer ring for 1st gear
^ Checking for wear
14. Synchronizer hub for 1st and 2nd gears
^ Pressing off
^ Pressing on
15. Circlip
^ Identification
^ Installation position, - item 1 -
^ Re-determining thickness when replacing synchronizer body
16. Needle bearing
^ For 2nd gear
17. Sliding sleeve for 1st and 2nd gear
^ Installation position
18. Synchronizer ring for 2nd gear
^ Checking for wear
19. Spring
^ Inserting in 2nd gear sliding gear
20. 2nd gear sliding gear
21. Circlip
^ Identification
^ Installation position, - item 2 -
22. 3rd-gear gear wheel
^ Pressing off
^ Pressing on
23. Circlip
^ Identification
^ Installation position, - item 3 -
^ If 3rd-gear gear wheel is replaced, re-determine thickness of circlip
24. 41th-gear gear wheel
^ Pressing off
^ Pressing on
25. Circlip
^ Identification
^ Installation position, - item 4 -
^ If 4th-gear gear wheel is replaced, re-determine thickness of circlip
26. Needle bearing
27. 51th gear sliding gear
28. Spring
^ Inserting in 5th gear sliding gear
29. Synchronizer ring for 51th gear
^ Checking for wear
30. Circlip
^ Identification
^ Installation position, - item 5 -
31. Synchronizer hub 5th gear and reverse gear
^ Pressing off
^ Pressing on
32. Circlip
^ Identification
^ Installation position, - item 6 -
^ Re-determining thickness when replacing synchronizer body
33. Needle bearing
^ For reverse gear
34. Sliding sleeve for 51th and reverse gear
^ Installation position
35. Synchronizer ring for reverse gear
^ Checking for wear
36. Spring
^ Inserting in reverse gear sliding gear
37. Sliding gear wheel for reverse gear
38. Circlip
^ Identification
^ Installation position, item 7
39. Tapered roller bearing inner race
^ Pressing off
^ Pressing on
40. Socket
^ Secures outer race for small tapered roller bearing
^ Pulling out
^ No longer needs to be installed after replacing small tapered roller bearing.
41. Tapered roller bearing outer race
^ Pressing out
^ Pressing in
42. Adjustment shim "S4"
43. Ring For mounting rubber washer
44. Rubber washer
^ Compensated length variations
45. Transmission cover
Pulling out outer race for double tapered roller bearing
^ Place pressure piece bushing puller 3128 under outer race.
^ Assemble threaded piece of bushing puller 3128 with pressure plate VW 401 onto transmission housing.
When bolt is tightened, the outer race will be pulled out of housing.
Pressing off inner race for double tapered roller bearing
^ Remove circlip before pressing off.
^ Outer race - A - must be installed to press off inner race.
Pressing in outer race for double tapered roller bearing
Smaller diameter of thrust pad 3062 points toward outer race.
Pressing on inner race for double tapered roller bearing
Determining circlip
^ Determine thickest circlip which can still just be installed and insert.
^ Circlips for synchronizer hubs, needle bearings and gear wheels of individual gears should be determined as for double tapered roller bearing as shown.
Available circlips and part numbers
Pulling out locking bushing for outer race for tapered roller bearing
A - Internal puller 12 to 14.5 mm, e.g. Kukko 21/1
Pressing out outer race for tapered roller bearing
^ Outer race is pressed out together with ring of adjustment shim "S4" and rubber washer for longitudinal compensation.
Pressing in tapered roller bearing outer race
Pressing off inner race for tapered roller bearing
^ Press off inner race together with reverse gear sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing on tapered roller bearing inner race
^ Before pressing on inner race, install circlip.
Pressing off synchronizer hub for 5th gear and reverse gear
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 5th gear sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off 4th-gear gear wheel
^ Remove circlip before pressing off.
Pressing off 3rd-gear gear wheel
^ Remove circlip before pressing off.
^ Press off 3rd-gear gear wheel with 2nd gear sliding 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 sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Installation position of circlips
^ Circlips for synchronizer hubs, needle bearings and gear wheels of individual gears should be determined as shown
Circlip - 1 - secures synchronizer hub 1st and 2nd gear.
Characteristic: Blue color
Circlip - 2 - secures needle bearing/2nd gear sliding gear
Characteristic: Blue color
^ Circlip - 3 - secures 3rd-gear gear wheel
^ Circlip - 4 - secures the 4thgear gear wheel
^ Circlip - 5 - secures needle bearing/5th gear sliding gear
Characteristic: Brown color
^ Circlip - 6 - secures synchronizer hub 5th and reverse gear.
Characteristic: Blue color
Circlip - 7 - secures needle bearing for reverse gear sliding gear.
Determine circlips according to table. Part numbers
Electronic Parts Catalog (ETKA)
Inserting spring into sliding gear
The bent end of spring - arrow - must be hooked into hole of sliding gear.
Checking synchronizer ring for wear
^ Press synchronizer ring into sliding sleeve and measure gap dimension - a - at positions - A -, - B - and - C - using a feeler gauge.
^ Add measured values and divide total by three to calculate average.
The calculated gap must not be less than 0.5 mm.
Pressing on synchronizer hub for 1st and 2nd gears
Installation position: High inner collar faces 2nd gear.
Installation position of sliding sleeve
^ Installation position:
Chamfer - arrow 1 - faces 2nd gear
Offset - arrow 2 - faces 1st gear
Pressing on 3rd-gear gear wheel
Installation position: The groove on gear wheel faces 4th gear.
Pressing on 4th-gear gear wheel
Installation position: High inner collar faces 3rd gear.
Pressing on synchronizer hub for 5th gear and reverse gear
Installation position: High inner collar faces 5th gear.
Installation position of sliding sleeve for 5th and reverse gear
Sliding sleeves with chamfer - A - as well as sliding sleeves with large offset - B - are installed.
^ Note allocation of sliding sleeve to reverse idler gear
^ Installation position:
Chamfer - arrow 1 - faces reverse gear
Small offset - arrow 2 - faces 5th gear Large offset - arrow 3 - faces reverse gear
Allocation of sliding sleeve to reverse idler gear