Pinion, Disassembling and Assembling: Overview

Pinion And Hollow Shaft, Disassembling And Assembling

WARNING: When replacing the tapered roller bearings, determine the installation position of the pinion (actual measurement) before removing it along with the hollow shaft.

Notes:
- When installing new gears or a new gear set, refer to "Application and Identification" and "Specifications".
- Because the circlips used differ in size and thickness, individual circlips must be marked (mark with numbers: refer to "Location of Clips on Hollow Shaft" within Procedures). The required thickness of a particular circlip must be re-determined whenever a directly affected component is replaced.






1. Transmission housing
2. Shim -S3-
- List of adjustments, refer to Differential.
3. Double tapered roller bearing outer race
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
4. Pinion
- Matched to differential ring gear
- If the gear set is replaced, the pinion with hollow shaft and the differential ring gear should be adjusted: refer to Differential.
5. Double tapered roller bearing inner race
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
- After measuring to determine thickness of shims S3 and S4, grease small bearing with MoS2 grease

CAUTION! Do not damage the sealing lips between the tapered roller bearings.

6. Needle bearing for hollow shaft
- Insert with MoS2 grease
7. Circlip
- Determining thickness: refer to "Procedures"
8. Hollow shaft
- When replacing hollow shaft, re-determine thickness of shim S4: refer to Differential
- Small bearing outer race is an integral part of the hollow shaft
9. Needle bearing for 1st gear
10. Needle bearing for 1st gear
11. 1st gear
- Insert spring before installing: refer to "Procedures"
- Press off together with synchronizer hub
12. Synchronizer ring for 1st gear
- Check for wear: refer to "Procedures"
13. Synchronizer hub for 1st and 2nd gear
- High inner shoulder faces 2nd gear
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
14.Circlip
- Location: refer to "Procedures"
- Determining: refer to "Procedures"
15.Needle bearing for 2nd gear
16.Circlip
- Location: refer to "Procedures"
- Determining: refer to "Procedures"
17. Operating sleeve for 1st and 2nd gear
- Installation position: refer to "Procedures"
18. Synchronizer ring for 2nd gear
- Check for wear: refer to "Procedures"
19. 2nd gear
- Insert spring before installing: refer to "Procedures"
20. 3rd gear
- Groove faces 4th gear
- Removing: refer to "Procedures"
- Inserting: refer to "Procedures"
- Pay attention to "General Repair Instructions" at Service and Repair.
21. Circlip
- Location: refer to "Procedures"
- Thickness: refer to "Procedures"
22. 4th gear
- Shoulder faces 3rd gear
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
- Pay attention to general repair instructions at "Service and Repair"
23. Circlip
- Location: refer to "Procedures"
- Determining: refer to "Procedures"
24. Needle bearing for 5th gear
25. 5th gear
- Insert spring before installing: refer to "Procedures"
26. Synchronizer ring for 5th gear
- Check for wear: refer to "Procedures"
27. Circlip
- Location: refer to "Procedures"
- Thickness: refer to "Procedures"
28. Synchronizer hub for 5th and reverse gear
- Removing together with 5th gear: refer to "Procedures"
- Press on with sleeve VW 519
- High inner shoulder faces 5th gear
29. Circlip
- Location: refer to "Procedures"
- Determining: refer to "Procedures"
30. Needle bearing for reverse gear
31. Operating sleeve for 5th and reverse gear
- Installation position: refer to "Procedures"
32. Synchronizer ring for reverse gear
- Check for wear: refer to "Procedures"
33. Reverse gear
- Insert spring before installing: refer to "Procedures"
34. Circlip
- Location: refer to "Procedures"
- Insert tapered roller bearing before installing inner race
- Insert before installing the tapered roller bearing inner race
35. Tapered roller bearing inner race
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
36. Tapered roller bearing outer race
- Removing: refer to "Procedures"
- Knock in with thrust pad 3062
37. Shim -S4-
- List of adjustments: refer to Differential
38. Pressure plate
39. Washer
- For heat-controlled length compensation
40. Transmission cover