Output Shaft
Output Shaft
Special tools, testers and auxiliary items required
•
• Punch (VW 407)
• Punch (VW 412)
• Thrust pad (VW 512)
• Puller (V.A.G 1582)
• Attachment (V.A.G 1582/4)
• Attachment (V.A.G 1582/5)
• Pressure plate (VW 402)
• Driver (32 - 111)
• Punch (VW 408 A)
• Punch (VW 409)
• Support channels (VW 457)
• Tube (VW 519)
• Thrust ring (VW 429)
• Tube (VW 415 A)
• Thrust pad (VW 447 H)
• Thrust piece (VW 454)
• Pressing sleeve (VW 455)
• Drive bushing (41-501)
• Internal puller (1- Kukko 21/6)
• Counter support (4- Kukko 22/2)
• Separating device (3- Kukko 17/2)
• The output shaft is disassembled as follows: Set separating device under the 2nd gear selector gear --> [ 21 2nd gear selector gear ] and press off as described in --> [ Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve ] Remove circlip --> [ (item 17) Securing ring ]. Then press off locking collar with 1st and 2nd gear synchronizer hub as described in --> [ Pressing off locking collar with synchronizer hub and bearing mount ]
• When installing new drive gears or input shaft, refer to Technical Data --> [ Codes Letters, Allocation and Capacities ] Application and ID
• Always replace both taper roller bearings together as a set.
1 Nut, 25 Nm plus an additional 90° turn
• 4 nuts for bearing mount
2 Clutch housing
3 Adjustment shim
• For output shaft
• Adjustment overview --> [ Adjustment Overview ] Adjustment Overview
4 Small tapered roller bearing outer race
• Removing --> [ Pulling off small outer race/tapered roller bearing ]
• Installing --> [ Pressing in small outer race/tapered roller bearing ]
5 Small tapered roller bearing inner race
• Pulling off --> [ Pulling off small inner race/tapered roller bearing ]
• Pressing on --> [ Pressing on small tapered roller bearing inner race ]
6 Output Shaft
• Adjusting --> [ Output Shaft, Adjusting ] Adjustments
7 Large tapered roller bearing inner race
• Pulling off --> [ Pulling off large inner race/tapered roller bearing ]
• Pressing on --> [ Pressing on inner race of large taper roller bearing ]
8 Seal
• Place seals (Qty. 4) on the bolts of the bearing mount
9 Bearing mount
• With large tapered roller bearing outer race and bolts
• Only change outer race together with large tapered roller bearing and bearing mount
10 Thrust washer
• Shoulder on thrust washer faces toward tapered roller bearing
11 1st gear selector gear
12 Needle bearing
• For 1st gear
13 Synchronizer ring
• (Inner race for 1st gear)
• Installation position --> [ Installation position of inner race, outer race and synchronizer ring for 1st gear ]
• Checking for wear --> [ Checking inner race of 1st gear and 2nd gear for wear ]
• Check tabs for scoring
14 Outer race for 1st gear
• Installation position --> [ Installation position of inner race, outer race and synchronizer ring for 1st gear ]
• Checking for wear --> [ Checking synchronizer ring of 1st gear and 2nd gear for wear ]
• Replace if grooved or scored
15 1st gear synchronizer ring
• Installation position --> [ Installation position of inner race, outer race and synchronizer ring for 1st gear ]
• Checking for wear --> [ Checking synchronizer ring of 1st gear and 2nd gear for wear ]
16 Locking sleeve with synchronizer hub for 1st and 2nd gears
• After removing circlip --> [ (item 17) Securing ring ] , press off with bearing mount --> [ Pressing off locking collar with synchronizer
hub and bearing mount ]
• Disassembling --> [ Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gear ]
• Assembling operating sleeve/synchronizer hub --> [ Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gear ] , --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces ] and --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with locking pieces that are not hollow ]
• Installation position --> [ Installation position of locking collar/synchronizer hub for 1st and 2nd gear ]
• Pressing on --> [ Pressing on locking collar/synchronizer hub for 1st and 2nd gear ]
17 Securing ring
18 2nd gear synchronizer ring
• Checking for wear --> [ Checking synchronizer ring of 1st gear and 2nd gear for wear ]
• Insert so that cut-outs engage in engagement pieces of locking collar --> [ 16 Locking sleeve with synchronizer hub for 1st and 2nd gears ]
19 Outer race for 2nd gear
• Insert into synchronizer ring --> [ 18 2nd gear synchronizer ring ]
• Installation position --> [ Installation position of 2nd gear outer race ]
• Replace if grooved or scored
20 Synchronizer ring
• (Inner race for 2nd gear)
• Checking for wear --> [ Checking synchronizer ring of 1st gear and 2nd gear for wear ]
• Check tabs for scoring
• Installation position --> [ Installation position of synchronizer ring (2nd gear inner race) ]
21 2nd gear selector gear
• Installation position --> [ Installation position of 2nd gear drive gear ]
22 Needle bearing
• For 2nd gear
23 Thrust washer
24 Sleeve for 3rd gear needle bearing
• Pressing off with 2nd gear selector gear --> [ Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve ]
• Pressing on --> [ Pressing on sleeve for 3rd gear needle bearing ]
25 Needle bearing
• For the 3rd gear
26 3rd gear selector gear
27 3rd gear synchronizer gear
• Checking for wear --> [ Checking synchronizer ring of 3rd gear and 4th gear for wear ]
28 Locking collar with synchronizer hub for 3rd and 4th gear
• Pressing off with 2nd gear drive gear --> [ 21 2nd gear selector gear ] and 3rd gear --> [ (item 26) 3rd gear selector gear ] --> [ Pressing off 3rd and 4th gear synchronizer
hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve ]
• Disassembling --> [ Disassembling and assembling locking collar and synchronizer hub for 3rd and 4th gear ]
• Assembling operating sleeve/synchronizer hub --> [ Disassembling and assembling locking collar and synchronizer hub for 3rd and 4th gear ] , --> [ Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with hollow locking pieces ] and --> [ Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with locking pieces that are not hollow ]
• Installation position of locking collar/synchronizer hub --> [ Installation position of locking collar/synchronizer
hub for 3rd and 4th gear ]
• Pressing on --> [ Pressing on synchronizer hub with locking collar for 3rd and 4th gears ]
29 Sleeve
• For needle bearing
• Pressing off with locking collar with synchronizer hub for 3rd and 4th gear --> [(item 28)Locking collar with synchronizer hub for 3rd and 4th gear ] --> [ Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve ]
• Pressing on --> [ Pressing on sleeve for 4th gear needle bearing ]
30 Needle bearing
• For 4th gear
31 Sychronizer ring for 4th gear
• Checking for wear --> [ Checking synchronizer ring of 3rd gear and 4th gear for wear ]
32 Selector gear for 4th gear
33 Thrust washer
34 Needle bearing
• For output shaft
• Removing and installing --> [ Drive out needle bearing. ] Transmission Housing and Clutch Housing, Servicing
35 Transmission housing
36 Sleeve
• For needle bearing/output shaft
• Pressing off --> [ Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve ]
• Pressing on --> [ Pressing on sleeve for output shaft needle bearing ]
37 5th gear gear-wheel
• Removing and installing --> [ Disassembly and Assembly Sequence ] Disassembly and Assembly Sequence
38 Plate spring
• Installation position --> [ Installation position of plate springs for 5th gear synchronizer hub and gear-wheel securing bolts ] Disassembly and Assembly Sequence
39 Screw --> [ 4 Bolt, 80 Nm plus an additional 90° ] Cover for Transmission Housing and 5th Gear
• Always replace
• Removing and installing --> [ Disassembly and Assembly Sequence ] Disassembly and Assembly Sequence
Pulling off small outer race/tapered roller bearing
A Internal puller 37 to 46 mm, e.g. (Kukko 21/6)
B Support, e.g. (Kukko 22/2)
Pressing in small outer race/tapered roller bearing
Pulling off small inner race/tapered roller bearing
A Protective jaws/vise
- Install gripping piece and tension thoroughly behind bearing rollers, then turn bearing and retention gripping piece.
Pressing on small tapered roller bearing inner race
Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear selector gears with needle bearing sleeve
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
B Hex bolt M10x20 with 17 mm head
• Support separating device so that the 1st and 2nd gear locking collar is not pulled off at the same time.
Pressing off locking collar with synchronizer hub and bearing mount
- First remove circlip - arrow -.
Pulling off large inner race/tapered roller bearing
A - Protective jaws
- Before installing puller, insert a bolt M10x20 in bore of the output shaft.
Pressing on inner race of large taper roller bearing
- A - Thrust washer
- Insert thrust washer before pressing on the inner race. The shoulder faces toward the inner race.
Installation position of inner race, outer race and synchronizer ring for 1st gear
- Place inner race - A - on drive gear for 1st gear.
The bent tabs - arrow 1 - face toward the outer race - B -.
- Install outer race - B -.
The tabs - arrow 2 - engage in notches - arrow 3 - of drive gear.
- Install synchronizer ring - C -.
The notches - arrow 4 - engage in the tabs - arrow 1 - of the inner race - A -.
• If the components are not to be replaced, make sure they are reallocated to their original gear.
Checking inner race of 1st gear and 2nd gear for wear
- Press inner race onto taper of drive gear and measure gap dimension - a - using a feeler gauge.
Checking synchronizer ring of 1st gear and 2nd gear for wear
- Press synchronizer ring, outer race and inner race onto taper of drive gear and measure gap dimension - a - using a feeler gauge.
Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gear
1 Spring
Assembly in conjunction with hollow locking pieces --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces ]
Assembly in conjunction with locking pieces that are not hollow --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with locking pieces that are not hollow ]
2 Locking collar
3 Synchronizer hub
4 Locking piece
The shoulder is the same width on both sides of the synchronizer hub.
The shoulder has a chamfer on one side - arrow B -.
After assembly, the chamfer on the shoulder of the synchronizer hub and the outer splines of the locking collar - arrow A - face the same direction.
Recesses for locking pieces on synchronizer hub and locking collar - arrow C - must align.
Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces
• The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset. Spring must engage with angled end into hollow engaging piece.
Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with locking pieces that are not hollow
• The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset. The angled end of the spring must be positioned in front of the locking pieces - arrows -.
Installation position of locking collar/synchronizer hub for 1st and 2nd gear
The teeth of the locking collar - arrow - point toward the splines of the 3rd/4th gear synchronizer hub - A -.
Pressing on locking collar/synchronizer hub for 1st and 2nd gear
Turn synchronizer ring so that the grooves align with the locking pieces.
Installation position of 2nd gear outer race
The tabs - arrows - face toward 1st gear - A -.
Installation position of synchronizer ring (2nd gear inner race) - A -
The tabs - arrow 1 - engage into the cut-outs - arrow 2 - of the synchronizer ring - B -.
Installation position of 2nd gear drive gear
The higher collar - A - faces toward 1st gear - B -. Cut-outs in collar - arrows - engage into outer race tabs --> [ Installation position of 2nd gear outer race ]
Pressing on sleeve for 3rd gear needle bearing
Checking synchronizer ring of 3rd gear and 4th gear for wear
- Press synchronizer ring onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Disassembling and assembling locking collar and synchronizer hub for 3rd and 4th gear
1 Spring
Assembly in conjunction with hollow locking pieces --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces ]
Assembly in conjunction with locking pieces that are not hollow --> [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with locking pieces that are not hollow ]
2 Locking piece
3 Locking collar
4 Synchronizer hub
- Slide locking collar over synchronizer hub.
The recesses for locking pieces in synchronizer hub and locking collar must align.
Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with hollow locking pieces
The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset. Spring must engage with angled end into hollow engaging piece.
Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with locking pieces that are not hollow
• The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset. The angled end of the spring must be positioned in front of the locking pieces - arrows -.
Installation position of locking collar/synchronizer hub for 3rd and 4th gear
Chamfer - arrow - faces toward 4th gear.
Pressing on synchronizer hub with locking collar for 3rd and 4th gears
Pressing on sleeve for 4th gear needle bearing
Pressing on sleeve for output shaft needle bearing
