Procedures

Removing Outer Race For Large Tapered Roller Bearing
- Place pressure piece from installing tool 3128 under bearing outer race.
- Install support bar VW 771/29 and M10 bolt on transmission housing.
When bolt is tightened, race will be pulled out of housing.






Pressing In Outer Race For Large Tapered Roller Bearing






Pressing Off Inner Race Of Large Tapered Roller Bearing
- To press off inner race, outer race -A- must be placed in position.






Pressing On Inner Race Of Large Tapered Roller Bearing






Fitting-Spring In Gear
- Install spring in gear and hook angled end (arrow) into hole.






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






Installation Position Of Operating Sleeve
- Smaller diameter side (arrow) faces toward 1st gear.






Pressing Off 3rd Gear
- A = Separator, 22-115 mm, e.g. Kukko 17/2
- Press gear off together with 2nd gear.






Pressing On 3rd gear
- Groove points toward 4th gear.






Pressing Off 4th Gear






Pressing On 4th Gear
- Shoulder points toward 3rd gear.






Pressing Off Synchronizer Hub
- A = Separator, 22-115 mm, e.g. Kukko 17/2
- Press off synchronizer hub with 5th gear.






Pressing Off Inner Race For Small Tapered Roller Bearing
- A = Separator, 22-115 mm, e.g. Kukko 17/2
- Press off inner race with reverse gear.






Pressing On Inner Race For Small Tapered Roller Bearing






Operating Sleeve For 5th And Reverse Gears
- Bevelled side (arrow -1-) toward reverse gear
- Side with smaller diameter (arrow -2-) toward 5th gear






Removing Locking Bushing From Outer Race Of Small Tapered Roller Bearing
- Use puller -A-, 12-16 mm, e.g. Kukko 21/2







Removing Outer Race Of Smaller Tapered Roller Bearing

Note: Use M10 stud approx. 50 mm (2 in.) long, reduced at one end to M8 (self-manufactured).

- Screw stud into plate, secure special tool and knock plate and outer race out of housing cover.






Pressing In Outer Race For Small Tapered Roller Bearing






Determining Circlip For Tapered Roller Bearing
- Determine thickest circlip possible that can be installed in groove, and install.
- Determine circlip thicknesses for 3rd and 4th gears and synchronizer hub in same way.
- Available circlips: refer to "Position of Circlips".






Position Of Circlips
- Determine thickness of circlips -1- and -2-, -4- and -5-, and -7-.
- Thickness of circlips -3- and -6- is constant (see tables).






Circlip -1-






Circlip -2-, Blue






Circlip-3-, Blue






Circlip -4-






Circlip -5-






Circlip 6, Brown






Circlip -7-, Blue