3rd and 4th Gear Output Shaft
3rd and 4th Gear Output Shaft
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Support Channels (VW 457)
• Thrust Pad (VW 510)
• Sleeve (VW 519)
• Holding Fixture (VW 801)
• Thrust Pad (30-11)
• Thrust Piece (40-105)
• Press Support (3118)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to V.A.G 1582 (V.A.G 1582/4)
• Grip (V.A.G 1582/7)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor 56-70 mm (21/8)
• Kukko Support (22/2)
• Feeler Gauge
Removing the Inner Race/Tapered Roller Bearing inside the Transmission Housing
- Mount the thrust pad 16.5/28 mm dia. (VW 431) in the output shaft and lay the thrust plate (40-105) on top of it before installing the puller.
- Remove the locking ring.
Removing 6th Gear
Removing the 5th and 3rd Gears
- Place the tools under the 3rd gear so that no other components can get damaged during removal.
• When removing, if the 5th gear is just in front of the - arrow -, then secure the output shaft from falling down.
- Remove the locking ring.
Removing the 3rd and 4th Gear Locking Collar/Synchronizer Hubs and the 4th Gear
Checking the 3rd and 4th Gear Inner Race for Wear
- Press the inner race onto the taper on the gear and measure the gap dimension - a - with a feeler gauge.
Checking the 3rd and 4th Gear Synchronizing Rings for Wear
- Install the synchronizer ring, outer race and inner race onto the taper of the elector gear and then measure the gap dimension - a - with a feeler gauge.
- Install the 4th gear with needle bearing.
Installed Position of the Outer Race, Inner Race and Synchronizer Ring, 4th Gear
- Install the inner race - A - on the 4th 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 -.
Disassembling and Assembling the Locking Collar and Synchronizer Hub for 3rd/4th Gears
- Remove the springs - 1 - for disassembling.
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub installed position, refer to => [ Installed Position: Locking Collar/Synchronizer
Hub for 3rd and 4th 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.
Assembling the Locking Collar/Synchronizer Hub for 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 3rd and 4th Gears
The taller collar of the synchronizer hub - arrow - faces 4th gear.
• The 4th gear is mounted on the shaft with the needle bearing and the synchronizer rings.
Installing the Locking Collar/Synchronizer Hub for 3rd and 4th Gears
- Install the locking ring.
Installed Position: 3rd Gear Outer Race
The tabs - arrows - face the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (3rd Gear Inner Race)
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
Installed Position: 3rd Gear
The higher collar - A - faces toward 4th gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position: 3rd Gear Outer Race ].
- Install the 3rd gear with the needle bearing.
- Heat the 5th gear to approximately 150 °C (302 °F).
Installing the 5th Gear
- Press the gear on quickly so that heat is not also transferred onto output shaft.
- Heat the 6th gear to approximately 150 °C (302 °F).
Installing the 6th Gear
- Insert the circlip.
• If, in the previous step, the 5th gear has been mounted, allow the output shaft to cool down.
- Press the gear on quickly so that heat is not also transferred onto output shaft.
- Install the circlip for the 6th gear.
Installing the Inner Race/Tapered Roller Bearing inside the Transmission Housing
• Removing the inner race/tapered roller bearing inside the transmission housing. Refer to => [ Removing the Inner Race/Tapered Roller
Bearing inside the Transmission Housing ].
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Support spindle, for example (22/2)
B Extractor 46-58 mm, for example (21/7)
- Install the new shim with the former size under the outer race.
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
Removing the Inner Race/Tapered Roller Bearing in the Clutch Housing
Installing the Inner Race/Tapered Roller Bearing in the Clutch Housing
- Mount the thrust pad (30-11) on the output shaft before removing the puller.
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Support, for example (22/2)
B Extractor 56-70 mm, for example (21/8)
- Install the new shim of the former size under the outer race.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing with the tube 60 mm dia. (VW 415 A) directly under the bearing mount.