1st and 2nd Gear Output Shaft
1st and 2nd Gear Output Shaft
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Arbor 50 mm Dia. (VW 432)
• Thrust Pad (VW 447 i)
• Tube 42 mm Dia. (VW 516)
• Thrust Pad (30-205)
• Thrust Piece (40-105)
• Thrust Plate (2050)
• Thrust Pad (3062)
• Press Support (3118)
• Thrust Washer (3401)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor 56-110 mm (21/89)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/1)
• Kukko Support (22/2)
• Kukko Support (22/4)
• 2-Arm Puller (20/10)
• Thrust Piece (T10266)
• Feeler Gauge
Removing the Dished Washer - C - from the Output Shaft
A Support, for example (22/1)
B Extractor 14.5-18.5 mm, for example (21/2)
• If the extractor comes out of the hole in the dished washer, then use the next larger extractor.
Install the dished Washer - A - all the Way into the Output Shaft - B -
- Install the thrust washer (3401) with the shoulder - arrow - on the dished washer - A -.
Press-in depth for the dished washer is approximately 2.20 mm.
- Remove the locking ring.
Removing the Inner Race/Tapered Roller Bearing and the 2nd Gear
- Switch the locking collar 1st/2nd gear to 1st gear.
- Attach the pulling hooks under the splines (not selector splines) for the 2nd gear.
A 2-arm puller, for example (20/10)
- Remove the locking ring.
Removing the 1st and 2nd Gear Locking Collar/Synchronizer Hub together with the 1st Gear
• Due to the fit between the synchronizer hub and the output shaft, these components can be remove by hand on some transmissions.
Removing the Axial Needle Bearing Thrust Washer - A -.
- Clamp the output shaft in a vise. Use jaw protectors. - B -.
- Remove the thrust washer alternating between sides from the output shaft using a drift - C - being careful not to damage the splines.
Installing the Axial Needle Bearing Thrust Washer - A -.
Installed Position: Axial Needle Bearing
- Place the larger axial needle bearing - 2 - on the output shaft thrust washer - 1 -.
• The needles must point upward toward the thrust washer - arrow A - and the flat side - arrow B -.
- Install the needle bearing - 3 - and 1st gear - 4 -.
- Install the smaller axial needle bearing - 5 - on the 1st gear.
• The needles must point upward toward the gear - arrow C - and the flat side - arrow D -.
Checking Inner Race for 1st and 2nd Gears for Wear
- Press the inner race onto the taper on the gear and measure the gap dimension - a - with a feeler gauge.
Checking the 1st and 2nd Gear Synchronizing Rings for Wear
- Install the synchronizer ring, outer race and inner race onto the taper of the selector gear and then measure the gap dimension - a - with a feeler gauge.
Installed Position: 1st Gear Outer Race, Inner Race and Synchronizer Ring
- Install the inner race - A - on the 1st gear.
• The angled tabs - arrows 1 - face the outer race - B -.
- Install the outer race - B -.
• The tabs - arrows 2 - must lock into the retainers - arrows 3 - in the gear.
- Install the synchronizer ring - C -.
• The retainers - arrows 4 - lock in the braces - arrows 1 - on the inner race - A -.
- Mount the smaller axial needle bearing (outer diameter: 58.7 mm) - 5 - on the 1st gear. Refer to => [ Installed Position: Axial Needle Bearing ].
Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears
- Remove the springs - 1 - for disassembling.
1. Spring
2. Locking piece
3. Locking collar installed position, refer to => [ Installed Position: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ].
4. Synchronizer hub installed position, refer to => [ Installed Position: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ].
- Slide the locking collar over the synchronizer hub.
• Installed position: The narrow recesses in the synchronizer hub align with the recesses in the locking collar.
Locking Collar Installed Position
Different locking collars are installed:
• The locking collar is pushed over the synchronizer hub.
- Install the locking pieces and springs offset by 120°.
• The angled end of the spring must engage into the hollow locking piece.
Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears
The high inner collar of the synchronizer hub - arrow - faces the 2nd gear.
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears and Installing the Locking Ring
Insert the 2nd gear synchronizer ring so that the cut-outs engage in the engagement pieces of locking collar.
Installed Position of the 2nd Gear Outer Race
The tabs - arrows - face the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (2nd Gear Inner Race)
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
- Install the 2nd gear needle bearing.
Installed Position: 2nd Gear
The higher collar - A - faces toward 1st gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position of the 2nd Gear Outer
Race ].
- Install the inner race/tapered roller bearing into the clutch housing. Refer to => [ Installing the Inner Race/Tapered Roller
bearing in the Clutch Housing ].
Installing the Inner Race/Tapered Roller Bearing in the Transmission Housing and Installing the Locking Ring
• Removing the inner race/tapered roller bearing inside the transmission housing. Refer to => [ Removing the Inner Race/Tapered Roller
Bearing and the 2nd Gear ].
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Support, for example, (22/2)
B Extractor 46-58 mm, for example, (21/7)
- After removing, install the new shim with the former size under the outer race.
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
- Support the transmission housing under the bearing mount using the arbor 50 mm dia. (VW 432).
Removing the Inner Race/Tapered roller Bearing in the Clutch Housing
A Separating tool 22-115 mm, for example (17/2)
Installing the Inner Race/Tapered Roller bearing in the Clutch Housing
- Install the locking ring.
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Support, for example (22/4)
B Extractor 56-110 mm, for example (21/89)
• To be able to mount the extractor - B - the oil deflector collar must be changed using a drift. Replace the damaged oil deflector ring.
• After removing, replace the damaged shim.
- Install the new oil deflector.
- Install the new shim with the former size under the outer race.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing using the tube 60 mm dia. (VW 415 A) directly under the bearing mount.