Reverse Gear Output Shaft
Reverse 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)
• Thrust Tube (VW 454)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Press Appliance (VW 459)
• Split Tube (VW 463/2)
• Thrust Piece (VW 473)
• Tube 42 mm Dia. (VW 516)
• Press Support (3118)
• Front and Rear Bearing Tool (3348)
• Thrust Washer (3401)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to V.A.G 1582 (V.A.G 1582/4)
• Tube Trans. Drive Shaft (VW 426)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Extractor 37-46 mm (21/6)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/1)
• Base Block (VW 441)
• Gearbox Holder (2004/1)
Remove the Dished Washer - C - from the Output Shaft
A Support, for example (Kukko 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 -
- Mount 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.
Removing the Inner Race/Tapered Roller Bearing inside the Transmission Housing
A Separating tool 22-115 mm, for example (17/2)
- Remove the locking ring.
Removing the Synchronizer Hub/Reverse Gear and Reverse Gear
- Mount the reverse gear with the needle and roller bearings on the output shaft.
Installed Position of the Synchronizer Hub for Reverse Gear
• The stop - arrow - faces the pressing tool.
Installing the Reverse Gear Synchronizer Hub
- Pressing on the synchronizer hub for the reverse gear.
- Install the locking ring.
Removing the Inner Race/Tapered Roller Bearing in the Clutch Housing
- Before installing the puller, set the thrust pad 16.5/28 mm dia. (VW 431) onto the output shaft.
Installing the Inner Race/Tapered Roller Bearing in the Clutch Housing
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
- Mount the sleeve (VW 459/1) over the bearing seat with collar facing the support - A -.
A Support, for example (22/2)
B Extractor 46-58 mm, for example (21/7)
After removing, replace the damaged shim.
- Install the oil deflector.
- Install the new shim with the former size.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing directly beneath the bearing mount using the thrust piece (VW 473).
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
The collar on the press support (3118) faces the support - A -.
A Support, for example (22/2)
B Extractor 37-46 mm, for example (21/6)
- Install the new shim of the former size under the outer race.
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
- Support the transmission housing beneath the bearing mount using the split tube (VW 463/2).
When positioning the split tube (VW 463/2) be careful of the housing rib.
The perforation in the base block (VW 441) - arrow - faces the split tube (VW 463/2).