Pinion, Disassembling and Assembling: Overview

CAUTION! If the tapered roller bearings are to be replaced, installation position of the pinion (the actual dimension) must be measured before it is removed: refer to Differential

Note: When installing new gears or a new gear set: refer to "Application and Identification" and "Specifications".

1. Transmission housing
2. Shim -S3-
- Adjustment table: refer to Differential
3. Outer race for large tapered roller bearing
4. Pinion
- Matched set with ring gear
- When gear set is replaced, pinion and ring gear must be adjusted: refer to Differential.
5. Inner race for large tapered roller bearing
6. Circlip
- Observe position: refer to "Position of Circlips" at Procedures.
- Determine thickness: refer to "Determining Circlip For Tapered Roller Bearing" at Procedures.
7. Needle bearing for 1st gear
8. 1st gear
- Install spring before installing: refer to "Fitting - Spring In Gear" at Procedures.
9. 1st gear synchronizer ring
- Check for wear: refer to "Checking Synchronizer Ring For Wear" at Procedures.
10. 1st/2nd gear synchronizer hub
- Higher shoulder faces toward 2nd gear
- Press off together with 1st gear using VW 401 and VW 402
- Press on with tube sections VW 415A and VW 519
11. Circlip
- Observe position: refer to "Position of Circlips" at Procedures.
- Determine thickness: refer to "Determining Circlip for Tapered Roller Bearing" at Procedures.
12. Needle bearing for 2nd gear
13. 1st/2nd gear operating sleeve
- Installation position: refer to "Installation Position Of Operating Sleeve" at Procedures.
14. 2nd gear synchronizer ring
- Check for wear: refer to "Checking Synchronizer Ring For Wear" at Procedures.
15. 2nd gear
- Install spring before installing: refer to "Fitting - Spring In Gear" at Procedures.
16. Circlip
- Observe position. Refer to "Position of Circlips" at Procedures.
- Observe thickness
17. 3rd gear
- Groove faces toward 4th gear
- Pressing off: refer to "Pressing Off 3rd Gear" at Procedures.
- Pressing on: refer to "Pressing On 3rd Gear" at procedures.
- Refer to "General Repair Instructions" at Service and Repair.
18. Circlip
- Position: refer to "Position of Circlips", at Procedures.
- Determine thickness: refer to "Determining Circlip For Tapered Roller Bearing" at Procedures.
19. 4th gear
- Shoulder points toward 3rd gear
- Pressing off: refer to "Pressing Off 5th Gear" at Procedures.
- Pressing on: "Pressing On 5th Gear" at Procedures.
- Refer to general repair instructions at "Service and Repair".
20. Circlip
- Observe position: Position of Circlips, at Procedures.
- Determine thickness: refer to Determining Circlip For Tapered Roller Bearing" at Procedures.
21. Needle bearing for 5th gear
22. 5th gear
- Install spring before installing: refer to "Fitting - Spring In Gear" at Procedures.
23. 5th gear synchronizer ring
- Check for wear: refer to "Checking Synchronizer Ring For Wear" at Procedures.
24. Circlip
- Position: refer to "Position of Circlips" at Procedures.
- Observe thickness: refer to "Position of Circlips".
25. 5th/Reverse gear synchronizer hub
- Press off with 5th gear: refer to Pressing Off Synchronizer Hub" at Procedures.
- Press on with tube 2010
- Higher inner shoulder faces toward 5th gear
26. Circlip
- Position: refer to "Position of Circlips", at Procedures.
- Determining: refer to "Determining circlip For Tapered Roller Bearing" at Procedures.
27. Needle bearing for Reverse gear
28. 5th/Reverse gear operating sleeve
- Installation position: refer to "Pressing Off Synchronizer Hub" at Procedures.
29. Reverse gear synchronizer ring
- Check for wear: refer to "Checking Synchronizer Ring For Wear" at Procedures.
30. Reverse gear
- Install spring before installing: refer to "Fitting - Spring In Gear". at Procedures.
31. Inner race for small tapered roller bearing
- Pressing off: refer to "Pressing Off Inner Race For Small Tapered Roller Bearing" at Procedures.
- Pressing on: refer to "Pressing On Inner Race For Small Tapered Roller Bearing" at Procedures.
32. Locking bushing
- For outer race of small tapered roller bearing
- Removing: refer to "Removing Locking Bushing From Outer Race Of Small Tapered Roller Bearing" at Procedures.
- Need not be installed after replacing outer race (required during production only)
33. Outer race for small tapered roller bearing
- Removing: refer to "Removing Outer Race For Small Tapered Roller Bearing: at Procedures.
- Pressing in: "Pressing in Outer Race For Small Tapered Roller Bearing" at Procedures.
34. Shim -S4-
- List of adjustments: refer to Differential
35. Thrust plate
36. Washer
- Compensates for length
- Variation due to heat
- To remove, drill hole in washer and pry out using self-tapping screw
37. Transmission cover

Note: Circlips of various sizes and thicknesses determine the precise installed positions of various components. As they are used, individual circlips must be marked (mark with numbers as shown in "Position of Circlips" at Procedures). Required thickness of individual circlips must be re-determined whenever a directly affected component is replaced.