Output Shaft, 5th, 6th and Reverse Gears
Output Shaft, 5th, 6th and Reverse 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)
• Transmission Support (VW 353)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Support Channels (VW 457)
• Holding Fixture (VW 801)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Tube (VW 455)
• Thrust Pad (VW 510)
• Tube 41 mm Dia. (VW 516)
• Sleeve (VW 519)
• Thrust Pad (30-11)
• Thrust Piece (40-105)
• Sleeve (40-20)
• Thrust Plate (2050)
• Tube (3296)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/4)
• Grip (V.A.G 1582/7)
• Inductive Heat Unit (VAS 6414)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
Removing the Outer Race/Tapered Roller Bearing
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)
• Check the washer for damage after removing it and replace if necessary.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Place the washer under the outer race.
- Support the clutch housing using the sleeve (40-20) directly under the bearing mount.
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
- Support the transmission housing under the bearing mount using the thrust plate (2050).
Disassembling the Output Shaft
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 transmission housing.
- Mount the thrust pad 16.5/28 mm dia. (VW 431) and thrust piece (40-105) on the output shaft.
Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar and the 6th Gear
- Remove the locking ring beforehand.
Removing the Sleeve - A - together with the Reverse Gear
- Remove the locking ring beforehand.
Removing the Reverse Gear Synchronizer Hub
- Remove the locking ring beforehand.
A Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
Removing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
- Mount the thrust pad (30-11) on the output shaft before removing the puller.
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.
Installed Position: Reverse Gear Synchronizer Hub
The stop - arrow A - on the reverse gear locking collar faces the splines on the output shaft - arrow B -.
Heating and Installing the Reverse Gear Synchronizer Hub
- Install the locking ring.
- Mount the reverse gear locking collar on the reverse gear synchronizer hub.
- Install the reverse gear and the needle bearing.
Installing the Sleeve - A -
Installed position: The wide collar points toward reverse gear selector gear.
- Install the locking ring.
Checking the 5th and 6th Gear Synchronizer Ring for Wear
- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - with a feeler gauge.
Disassembling and Assembling the Locking Collar and Synchronizer Hub for 5th and 6th Gears
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.
Assembling the Locking Collar/Synchronizer Hub for 5th and 6th 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.
- Install the 6th gear with needle bearing.
- Install the 6th gear synchronizer ring.
Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears
On some locking collars, there is a chamfer on the outer diameter.
Installed position: The chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
- Install the 5th gear synchronizer ring.
- Install 5th gear selector gear with needle bearing.
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.
- Select the locking ring according to the table. For the correct part number, refer to the Parts Catalog.
Available Locking Rings
Installing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
