Output Shaft, 5th, 6th and Reverse Gears
Output Shaft, 5th, 6th and Reverse Gears
Special tools, testers and auxiliary items required
• Pressure Plate (VW 401)
• Pressure Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Punch (VW 412)
• Sleeve (VW 415 A)
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Thrust Piece (VW 433)
• Thrust Piece (VW 454)
• Support Channels (VW 457)
• Holding Plate (VW 801)
• Thrust Piece (VW 431)
• Pressing Sleeve (VW 455)
• Thrust Pad (VW 510)
• Sleeve (VW 516)
• Sleeve (VW 519)
• Thrust Piece (30 - 11)
• Thrust Piece (40 - 105)
• Seal Driver-Front Wheel Bearing (40 - 20)
• Thrust Piece (2050)
• Tube (3296)
• Taper Roller Bearing Puller (V.A.G 1582)
• Attachment (V.A.G 1582/4)
• Attachment (V.A.G 1582/7)
• - 1 - Internal Puller (Kukko 21/7)
• - 3 - Separating Tool (Kukko 17/2)
• - 4 - Counter-Support (Kukko 22/2)
Pulling Out the Outer Race for Tapered Roller Bearing
A Counter Support (Kukko 22/2)
B Internal Puller 46 to 58 mm (Kukko 21/7)
• After removing, check the shim for damage and replace if necessary.
Pressing Outer Race for Tapered Roller Bearing into Clutch Housing
- Install shim under outer race.
- Support the clutch housing with the Sleeve (40 - 20) directly under the bearing mount.
Pulling Off Inner Race for Tapered Roller Bearing
- Remove circlip.
- Before attaching extractor, place Thrust Piece (VW 431) and Thrust Plate (40 - 105) on output shaft.
Pressing Off Synchronizer Hub/Locking Collar for 5th and 6th Gear with Selector Gear for 6th Gear
- Before pressing off, remove circlip.
Pressing Off Sleeve - A - Over Reverse Gear Selector Gear
- Before pressing off, remove circlip.
Pressing Off Synchronizer Hub for Reverse Gear
- Before pressing off, remove circlip.
A Separating Device 22 to 115 mm (Kukko 17/2)
Pulling Off Inner Race for Tapered Roller Bearing
- Before installing puller, set Thrust Piece (30 - 11) onto output shaft.
Installation Position of Synchronizer Hub for Reverse Gear
• Stop - arrow A - for reverse gear locking collar points toward output shaft splines - arrow B -.
Pressing on Synchronizer Hub for Reverse Gear
- Then install circlip.
Press on Sleeve - A -
• Installation position: Wide collar points toward reverse gear selector gear.
- Then install circlip.
Checking Synchronizer Ring for 5th and 6th Gears for Wear
- Press synchronizer ring onto taper of selector gear and measure gap dimension - a - using a feeler gauge.
Disassembling and Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gear
- Remove the springs to disassemble - 1 -.
2 Locking piece
3 Locking collar
4 Synchronizer hub
- To assemble, slide locking collar over the synchronizer hub.
• Installation position: The narrow recesses - arrow A - in the synchronizer hub align with the recesses - arrow B - in the locking collar.
Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears
• 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 engage into the hollow locking piece.
Pressing on Locking Collar/Synchronizer Hub for 5th and 6th Gears
- Then install circlip.
Pressing on Tapered Roller Bearing Inner Race
- Then, determine the circlip and install.
Determining Circlip
- Select and install the thickest, but yet still installable, retaining ring; for the part number, refer to the Parts Catalog.
Pressing on Tapered Roller Bearing Inner Race
Pulling Outer Race for Tapered Roller Bearing Out of Transmission Housing
A Counter support (Kukko 22/2)
B Internal puller 46 to 58 mm (Kukko 21/7)
Pressing Outer Race for Tapered Roller Bearing into Transmission Housing
- Support the transmission housing with the Thrust Plate (2050) under the bearing mount.