Part 1
Output Shaft, 1st to 4th Gears
=> [ Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization ]
=> [ Assembling, through Transmission Build Date 25 October 2009 ]
=> [ Assembling, from Transmission Build Date 26 October 2009 through 24 May 2010 ]
=> [ Assembling, from Transmission Build Date 25 May 2010 ]
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408A)
• Thrust Disc (VW 412)
• Tube 60 mm dia. (VW 415A)
• Holding Plate (VW 309)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Pad 16.5/28 mm dia. (VW 431)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Thrust Pad (VW 512)
• Tube 42 mm Dia. (VW 516)
• Sleeve (VW 519)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Thrust Piece (40-105)
• Sleeve (40-20)
• Sleeve (40-21)
• Thrust Plate (2050)
• Spacers (VW 540/1 B)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor (Kukko 21/8)
• Kukko Puller (18/2)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
Disassembly
Removing the Dished Washer - A - from the Output Shaft
Installing the Dished Washer onto the Output Shaft
"a" = 2 mm
Removing the Inner Race/Tapered Roller Bearing on the side of the Clutch Housing
A Separating tool, for example, Kukko separating tool 22-115 mm (17/2)
Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Counter support, for example, Kukko support (22//2)
B Internal puller 56-70 mm, for example, Kukko extractor (Kukko 21/8)
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing using the sleeve (40-20) directly under the bearing mount.
Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
Before installing the tapered roller bearing puller:
- Remove the inner race/tapered roller bearing locking ring on the side facing the clutch housing.
- Install the thrust pad 16.5/28 mm dia. (VW 431) on the output shaft and the thrust piece (40-105).
Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
- Choose the correct locking ring, refer to => [ Selecting the Locking Ring ] and install.
Selecting the Locking Ring
- Choose and install the thickest locking ring that will fit.
• For the correct locking rings, refer to the Parts Catalog.
The following locking rings are available:
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Counter support , for example, Kukko support (22/2)
B Internal puller 46 to 58 mm , for example, Kukko extractor 46-58 mm (21/7)
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
- Install the adjusting shim under the outer race.
- Support the transmission housing under the bearing mount using the thrust plate (2050).
Disassembling the Output Shaft
• Removing the inner race/tapered roller bearing on the side of the clutch housing. Refer to => [ Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing ].
Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear
- Remove the locking ring beforehand.
A Puller, for example, Kukko puller (80-210 mm (18/2)
B Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
- Remove the thrust washers for 1st and 4th gears => [ (Item 19) Thrust Washer ] Output Shaft, 1st to 4th Gears Overview and => [ (Item 20) Washer ] Output Shaft, 1st to 4th Gears Overview.
- Remove 1st gear => [ (Item 18) 1st Gear ] Output Shaft, 1st to 4th Gears Overview.
Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear
After removing the circlip, press off selector gear for 2nd gear and locking collar/synchronizer hub together.
Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization
1st/2nd gear synchronization through transmission build date 25 October 2009 and 3rd gear synchronization through transmission build date 24 May 2010
1st/2nd gear synchronization from transmission build date 26 October 2009 and 3rd gear synchronization from transmission build date 25 May 2000
