Output Shaft, 1st to 4th Gears
Output Shaft, 1st to 4th Gears
=> [ Differentiating 1st/2nd Gear Synchronization ]
=> [ Assembling, through Transmission Build Date 25 October 2009 ]
=> [ Assembling, from Transmission Build Date 26 October 2009 ]
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415A)
• 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 540/1 B)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor (21/8)
• Kukko Puller (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 Into the Output Shaft
Dimension "a" = 2 mm
Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
A Kukko separating tool 22-115 mm , for example, (17/2)
Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
Removing the Outer Race / Tapered Roller Bearing from the Clutch Housing
A Kukko support , for example, (22/2)
B Kukko extractor , for example, (Kukko 21/8)
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing with the (40-20) directly under the bearing mount.
Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
Before installing the tapered roller bearing puller :
- Remove the inner race/tapered roller bearing locking ring on the side facing the clutch housing.
- Mount the (VW 431) in the output shaft and lay the (40-105).
Installing the 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 Kukko support , for example, (22/2)
B Kukko Extractor 46-58 mm , for example, (Kukko 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 (2050).
Disassembling the Output Shaft
• Removing the inner race/tapered roller bearing on the side of the clutch housing. Refer to => [ Remove the 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 Kukko Puller , for example, (18/2)
B Kukko Separating Tool 22-115 mm , for example, (17/2)
Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear
After removing the circlip, press off selector gear for 2nd gear and locking collar/synchronizer hub together.
Differentiating 1st/2nd Gear Synchronization
• Through transmission build date 25 10 9, refer to => [ Synchronizing 1st/2nd Gear through
Transmission Build Date 25 10 9 ]
• From transmission build date 26 10 9, refer to => [ Synchronizing 1st/2nd Gear from Transmission
Build Date 26 10 9 ]
Synchronizing 1st/2nd Gear through Transmission Build Date 25 10 9
Synchronizing 1st/2nd Gear from Transmission Build Date 26 10 9
Assembling, through Transmission Build Date 25 October 2009
Checking the Inner Race for 1st, 2nd and 3rd Gear for Wear
- Check the tabs on the inner race for scoring.
- Install the inner race onto taper of selector gear and then measure gap dimension - a - with a feeler gauge.
Checking the 1st, 2nd and 3rd Gear Synchronizer Rings for Wear
- Install the synchronizer ring, outer race and inner race onto taper of selector gear and then measure the gap dimension - a - with a feeler gauge.
- Install the 2nd gear with the needle bearing.
Installed Position: 2nd Gear Outer Race, Inner Race and Synchronizer Ring
- Check the tabs - arrows 1 and 2 - for scoring.
- Replace the inner race, the outer race and the synchronizer ring if they have grooves or scoring.
- Install the inner race - A - on the 2nd 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 tabs - arrows 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.
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears.
Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
Install the synchronizer ring for 1st gear.
Installation Position of 1st Gear Outer Race
The tabs - arrows - face the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (1st gear inner race)
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
Install 1st Gear with Needle Roller Bearing
The higher collar - A - faces 2nd gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installation Position of 1st Gear Outer
Race ].
- Install the thrust washers for 1st and 4th gears - item 19 - => [ (Item 19) Thrust Washer ] and - item 20 - => [ (Item 20) Washer ] .
- 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 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.
Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.
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 the 4th gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installation Position of 1st Gear Outer
Race ].
- Install the 3rd gear with the needle bearing.
• Pressing on inner race/tapered roller bearing. Refer to => [ Installing the Inner Race/Tapered Roller
Bearing on the Side of the Transmission Housing ].
• Selecting the locking ring for the inner race/tapered roller bearing. Refer to => [ Selecting the Locking Ring ].
Assembling, from Transmission Build Date 26 October 2009
Checking the Inner Contact Surface for Wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- Install the inner race - 1 - on the cone on the gear.
- Push the outer race - 2 - onto the inner race cone and measure the gap dimension - a - at 3 places, offset by 120°, using a feeler gauge.
- Write down the average value.
Checking the Outer Contact Surface for Wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- 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 at 120°.
- Write down the average value.
- Install the 2nd gear with the needle bearing.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- Install the inner race - A - in the gear.
The tabs - 1 - face away from the gear.
- Install the outer race - B -.
The tabs - 2 - engage in 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.
- Insert the locking pieces and install the springs offset by 120°. The angled end of the spring must take hold in the hallow 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.
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 - in the 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 thrust washers for 1st and 4th gears - item 19 - => [ (Item 19) Thrust Washer ] and - item 20 - => [ (Item 20) Washer ] .
- Install the 4th gear with needle bearing.
Checking the 4th Gear Synchronizer Ring for Wear
- Press synchronizer ring onto taper of the gear and measure 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.
Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
Checking the 3rd Gear Inner Race for Wear
- Install the inner race onto taper of selector gear and then measure gap dimension - a - with a feeler gauge.
Checking Synchronizer Ring for 3rd Gear for Wear
- Install the synchronizer ring, outer race and inner race onto taper of selector gear and then measure the gap dimension - a - with a feeler gauge.
- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.
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 => [ Installation Position of 1st Gear Outer
Race ].
- Install the 3rd gear with the needle bearing.
• Installing the inner race/tapered roller bearing. Refer to => [ Installing the Inner Race/Tapered Roller
Bearing on the Side of the Transmission Housing ]
• Selecting the locking ring for the inner race/tapered roller bearing. Refer to => [ Selecting the Locking Ring ].