Output Shaft, 1st to 4th Gears
Output Shaft, 1st to 4th Gears
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)
• 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 540/1B)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Inductive Heat Unit (VAS 6414)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor 56-70 mm (21/8)
• Kukko Puller 80-210 mm (18/2)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
Removing the Dished Washer - A - from the Output Shaft
Installing the Dished Washer onto the Output Shaft
- a - = 2 mm
Removing the Bearing Inner Race/Tapered Roller Bearing on the side of the Clutch Housing
A Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
Installing the Bearing 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 to 70 mm, for example, Kukko extractor 56-70 mm (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 Bearing Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
Before installing the tapered roller bearing puller:
- Remove the bearing 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) in the output shaft and lay the thrust piece (40-105) on it.
Installing the Bearing 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 bearing inner race/tapered roller bearing on the side of the clutch housing. Refer to => [ Remove the Bearing 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 too 22-115 mm (17/2)
Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear
After removing the locking ring, press off the selector gear for 2nd gear and the locking collar/synchronizer hub together.
Assembling the Output Shaft
• Heat the tapered roller bearing inner races and synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) before installing. Press on until seated when installing, so there is no axial clearance.
Checking the Inner Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer Ring, and the 3rd Gear Outer Ring
- Install the inner race - 1 - on the cone on the gear.
- Install the outer race - 2 - on the cone on the inner race. Measure the gap - a - with a feeler gauge at 3 locations 120° apart.
- Note the average value.
Checking the Outer Contact Surface for Wear on the 1st Gear Outer Ring, the 2nd Gear Outer Ring, and the 3rd Gear Outer Ring
- Check the synchronizer ring - arrow - on the inner running surface for grooves and radial wear, and replace if necessary.
- Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.
- Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.
- Measure the gap - a - with a feeler gauge at 3 locations 120° apart.
- Note the average value.
- Install the 2nd gear with the needle bearing.
Installed Position of the Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- Place the inner race - A - on the drive gear for 2nd gear.
The tabs - 1 - face away from the gear.
- Install the outer race - B -.
The tabs - 2 - engage in the grooves - 3 - on the gear.
- Install the synchronizer ring - C -.
The larger openings - 4 - lock in the tabs - 1 - on the inner race - A -.
Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.
The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.
Assembly: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears
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 identification groove - arrow 1 - and the narrow collar - arrow 2 - on the synchronizer hub face 1st gear.
Heating and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears
The pins - A - on the synchronizer ring lock into the recesses - B - in the synchronizer hub.
- Install the locking ring.
Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race
- Install the synchronizer ring - A - into the 1st and 2nd gear synchronizer hub.
The tabs - 1 - lock in the openings - 2 - in the synchronizer hub.
- Install the outer race - B - in the synchronizer ring.
The tabs - 3 - face away from the synchronizer ring.
- Install the inner race - C - in the outer race.
The tabs - 4 - lock in the larger openings - 5 - in the synchronizer ring - A -.
Install 1st Gear with Needle Roller Bearing
• The synchronizer ring - 1 - and the tabs - arrow A - are inside the openings in the synchronizer hub - 2 -.
The pins - arrows B - in the outer race lock in the recesses - arrows C - in the gear - 3 -.
- Install the 1st and 4th gear thrust washers - items 19 and 20 - in => [ Output Shaft, 1st to 4th Gears Overview ] Output Shaft, 1st to 4th Gears Overview in the output shaft.
- Install the 4th gear with needle bearing.
Checking the 4th Gear Synchronizer Ring for Wear
- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.
Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears
The wider collar on the synchronizer hub - arrow - faces 3rd gear.
- Place the synchronizer ring for 4th gear on the 4th gear selector gear.
Heating and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the 4th gear synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
Installing the Outer Ring Synchronizer Ring and 3rd Gear Inner Ring
- Install the synchronizer ring - A - into the 3rd and 4th gear synchronizer hub.
The tabs - 1 - lock in the openings - 2 - in the synchronizer hub.
- Install the outer race - B - in the synchronizer ring.
The tabs - 3 - face away from the synchronizer ring.
- Install the inner race - C - in the outer race.
The tabs - 4 - lock in the larger openings - 5 - in the synchronizer ring - A -.
Install the 3rd Gear Selector Gear with Needle Bearing
• The synchronizer ring - 1 - and the tabs - arrow A - are inside the openings in the synchronizer hub - 2 -.
The pins - arrows B - in the outer race lock in the recesses - arrows C - in the gear - 3 -.
- Install the 3rd gear with the needle bearing.
• Installing the bearing inner race/taper roller bearing, refer to => [ Installing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing ].
• Selecting the locking ring for the bearing inner race/tapered roller bearing. Refer to => [ Selecting the Locking Ring ].