Procedures

Removing Needle Bearing For Input Shaft






Pressed-In Depth For Needle Bearing
- Dimension -a- from lower edge of straight-edge to upper edge of bearing: 39.5 mm (1.555 in.)






Installing 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 measured values together and divide by 3.
- Resulting average must not be less than 0.5 mm (0.020 in)






Position Of Operating Sleeve
- Reduced-diameter side (arrow) points toward 3rd gear.






Pressing Off 5th Gear
- A = Separating tool, 22-115 mm, e.g. Kukko 17/2






Pressing On 5th Gear
- Higher shoulder points toward reverse gear
- Oil pockets point toward 4th gear






Removing Needle Bearing For Input Shaft
- Use special tool VW 771 and inside puller -A-, 22-28 mm, e.g. Kukko 21/4.

Note: Destroy plastic sleeve before installing puller: see exploded view at "Overview", item 20.






Determining Thickness Of 4th Gear Circlip
- Determine thickest circlip possible that can be installed in groove then install.
- Determine 5th gear circlip in same way.
- Available circlips: see "Position of Circlips" below.






Position Of Circlips
- Thicknesses of circlips -1-, -2-, -4- and -5- must be determined. Circlip -3- is always the same thickness.
- Determining thickness of circlips -1- and -2-, refer to Input shaft, adjusting.
- Circlip -3-, brown; Part No. N 902 945.01; 2 mm thick






- Circlip -4-, blue






- Circlip -5-






Installation Position Of Needle Bearing For Input Shaft
- Dimension -a- = 216 mm (8.50 in.)






Pressing Off Synchronizer Hub For 3rd And 4th Gears
- A - Separating tool, 22-115 mm, e.g. Kukko 17/2

Note: Press synchronizer ring for 3rd speed (arrow) toward gear for 3rd speed before fitting separating tool.






Pressing On 3rd/4th Gear Synchronizer Hub