Bearing Plate, Servicing

Bearing plate, servicing
Special tools, testers and auxiliary items required:
^ Internal puller 18.5-23.5 mm (e.g. Kukko
^ Counter support (e.g. Kukko 22/1)
^ Press tool VW 408a
^ Guide pin 10-15
^ Thrust pad 30-504
^ Depth gauge





1. Bearing plate
^ If replacing, redetermine shim "S4"
2. Outer race for tapered roller bearing for drive pinion
^ Driving out, Refer to Overhaul Subassemblies, Drive Pinion and Hollow Shaft, Disassembling and Assembling
^ Pressing in, Refer to Overhaul Subassemblies, Drive Pinion and Hollow Shaft, Disassembling and Assembling
^ If replacing, redetermine shim "S4"
3. Shim "S4"
^ Adjustment overview, Refer to differential Assembly, Adjustments
^ Redetermining, Refer to Shim "S4," RE-Determining
4. Cylinder roller bearing for input shaft
^ Pressing out, Refer to Fig.
^ Pressing in, Refer to Fig. 6
^ Measuring insertion depth, Refer to Fig. 7
5. Ball sleeve
^ For selector rods
^ Removing and installing, Refer to Fig. 11
^ Replace
6. Bolt, 35 Nm
^ For relay lever
7. Dowel pin (7 x 28)
^ Press in flush
8. Sliding gear for reverse gear
9. Synchroring for reverse gear
^ With locking pins
^ Checking for wear, Refer to Fig. 2
^ Installation position: flat on circumference of synchroring faces towards input shaft, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and Installing (Assembly Sequence)
10. Spring
^ Installation position: hook single angled end into recess on synchroring. Turn double angled end anticlockwise and insert into opening on bearing plate.
11. Shaft for reverse sliding gear
12. Retaining plate
^ Installation position: the chamfers of the holes for the locking pins of the synchro ring towards bearing plate, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and Installing (Assembly Sequence)
13. Spring clasp
14. Bolt, 25 Nm
^ Self-locking
^ Replace
15. Relay lever for reverse gear
16. Follower for reverse gear
^ Pulling out ball sleeve, Refer to Fig. 3
^ Driving in ball sleeve, Refer to Fig. 4
17. Selector rod for 5th and 6th gear
^ Replace only complete with follower, Refer to 5TH and 6TH Gear, Removing and Installing





Fig. 1 Removing and installing ball sleeves for selector rods it
^ Insertion depth a = 2.5 mm





Fig. 2 Checking synchro-ring for wear
- Press synchro-ring onto cone of gear.
- Measure gap "a" with a feeler gauge:
^ Dimension, new: 0.75-2.3 mm
^ Wear limit: 0.2 mm





Fig. 3 Pulling ball sleeve out of follower for reverse gear
A - Counter support, e.g. Kukko 22/1
B - Internal puller 18.5-23.5 mm, e.g. Kukko 21/3





Fig. 4 Driving ball sleeve flush into follower for reverse gear





Fig. 5 Pressing cylinder roller bearing for input shaft out of bearing plate





Fig. 6 Pressing cylinder roller bearing for input shaft into bearing plate
Insertion depth depends on serial number of transmission.
Measuring insertion depth, Refer to Fig. 7.





Fig. 7 Measuring insertion depth of cylinder roller bearing for input shaft
a = 7 mm