Procedures

Removing Double Tapered Roller Bearing Outer Race
- Place thrust piece of bushing puller 3128 below outer race.
- Place supporting bar VW 771/29 and M10 bolt onto transmission housing.

When the bolt is tightened, the outer race is pulled out of the transmission housing.






Removing Tapered Roller Bearing Outer Race
- Press out along with pressure plate, shim and washer for length compensation.






Removing Double Tapered Roller Bearing Inner Race
- The outer race -A- must be installed to press off the inner race.






Installing Double Tapered Roller Bearing Inner Race
- Secure double tapered roller bearing as described below






Determining Circlip For Double Tapered Roller Bearing/Pinion






- Determine the thickest circlip that can just be inserted, and install.






Location Of Circlips On Hollow Shaft
- Determine thickness of circlips for synchronizer hubs and for 3rd and 4th gears using same method as described for double tapered roller bearing/pinion.
- Circlips -2-, -5- and -7- are always the same thickness: refer to Table. The following circlips are available for the hollow shaft:






- Circlip -1-, color: blue






- Circlip -2-, color: blue






- Circlip -3-






- Circlip -4-






- Circlip -5-, color: brown






- Circlip -6-, color: blue






- Circlip -7-






Removing Small Tapered Roller Bearing Inner Race
- Press off inner race together with reverse gear.
- A = Separation device, 22-115 mm, e.g. Kukko 17/2






Removing Synchronizer Hub
- Press off synchronizer hub together with 5th gear.
- A = Separation device, 22-115 mm, e.g. Kukko 17/2






Removing 4th Gear






Removing 3rd Gear
- Press off gear together with 2nd gear.
- -A- = Separation device, 22-115 mm, e.g. Kukko 17/2






Removing Synchronizer Hub For 1st And 2nd Gear
- Press off synchronizer hub together with 1st gear.






Placing Spring Into Gear
- Place spring (arrow) into gear by hooking angled end into hole.






Checking Synchronizer Ring For Wear
- Press synchronizer ring into operating sleeve and measure gap -a- with feeler gauge in positions -A-, -B- and -C-.
- Add readings together and divide by 3 to obtain average.
- The result must not be less than 0.5 mm (0.020 in).






Installation Position Of Operating Sleeve
- Chamfered face (arrow -1-) faces 2nd gear
- Side with reduced diameter (arrow -2-) faces 1st gear






Installing Synchronizer Hub For 1st And 2nd Gear
- High inner shoulder faces 2nd gear.






Installing 3rd Gear
- Groove faces 4th gear.






Installing 4th Gear
- Shoulder faces 3rd gear.






Operating Sleeve For 5th And Reverse Gear
- Chamfered face (arrow -1-) faces reverse gear
- Side with reduced diameter (arrow -2-) faces 5th gear






Installing Tapered Roller Bearing Inner Race
- Install circlip before pressing on inner race. Thickness of circlip: refer to "Location Of Circlips On Hollow Shaft" as described above.






Installing Double Tapered Roller Bearing Outer Race In Transmission Housing
- The outer race for double tapered roller bearing/pinion shaft side is an integral part of the hollow shaft.