Output Shaft, Disassembling and Assembling
Output shaft, disassembling and assembling
Special tools and workshop equipment required
^ VW 407 Press tool
^ VW 412 Press tool
^ VW 512 Press disk
^ V.A.G 1582 Puller
^ V.A.G 1582/4 Grip piece
^ V.A.G 1582/5 Grip piece
Special tools and workshop equipment required
^ VW 402 Press plate
^ 32 111 Thrust piece
^ VW 408 A Press tool
^ VW 407 Press tool
^ VW 457 Support rails
^ 3146 Tube
Special tools and workshop equipment required
^ VW 429 Thrust ring
^ VW 415 A Tube
^ VW 447 H Press plate
^ VW 454 Press piece
^ VW 455 Fitting sleeve
^ 41 501 Drift sleeve
Notes: The output shaft is dismantled as follows:
- Position separating device under 2nd gear (item 19) and press off as described in 5.
- Remove circlip (item 15).
- Position two - arm puller under bearing support (item 9) and pull off locking collar with 1st and 2nd gear synchro - hub as described in -Fig. 6.
- When installing new gears or a new output shaft consult technical data.
- Both taper roller bearings must be replaced together as a set.
1. Hexagon nut, 25 Nm and then turn 90° further
^ 4 nuts for bearing support
2. Clutch housing
3. Shim
^ For output shaft
^ Adjustment overview , Refer to Differential Assembly, Adjustments
4. Small taper roller bearing outer race
^ Removing, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
5. Small taper roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on , Refer to Fig. 4
6. Output shaft
^ Is paired with final drive gear, always replace together as a set
^ Adjusting, Refer to Overhaul Subassemblies, Output Shaft Adjusting
7. Large taper roller bearing inner race
^ Pulling off, Refer to Fig. 7
^ Pressing on, Refer to Fig. 5
8. Sealing ring
^ Place sealing rings (Qty. 4) on the bearing support bolts
9. Bearing support
^ With large taper roller bearing outer race and bolts
^ Only replace outer race together with large taper roller bearing and bearing support
10. Thrust washer
^ Shoulder on thrust washer faces taper roller bearing
11. 1st gear
12. Needle roller bearing
^ For 1st gear
13. 1st gear synchro - ring
^ Checking for wear
^ Identification, Refer to Fig. 14
14. 1st and 2nd gear locking collar with synchro - hub
^ Pull off via bearing support after removing circlip (item 15 , Refer to Fig. 6
^ Disassembling, Refer to Fig. 10
^ Assembling locking collar/synchro hub, Refer to Fig. 10 and Fig. 11
^ Installation position, Refer to Fig. 12
^ Pressing on, Refer to Fig. 13
15. Circlip
16. 2nd gear synchro
^ Identification, Refer to Fig. 14
^ Checking for wear, Refer to Fig. 16
^ Assemble so that the recesses locate in the locking collar (item 14) locking pieces
17. Outer ring
^ Insert in the synchro - ring (item 16), installation position, Refer to Fig. 17
^ Replace if scored
18. Synchro - ring
^ Inner ring
^ Checking for wear, Refer to Fig. 18
^ Check lugs for scoring
^ Installation position, Refer to Fig. 19
19. 2nd gear
^ Installation position, Refer to Fig. 20
20. Needle roller bearing
^ For 2nd gear
21. Thrust washer
22. Sleeve for 3rd gear needle roller bearing
^ Pressing off with 2nd gear
^ Pressing on, Refer to Fig. 21
23. Needle roller bearing
^ For 3rd gear
24. 3rd gear
25. 3rd gear synchro - ring
^ Checking for wear - Ago
26. Locking collar with 3rd and 4th gear synchro - hub
^ Press off with 2nd gear (item 19) and 3rd gear (item 24), Refer to Fig. 5
^ Disassembling, Refer to Fig. 22
^ Installation position locking collar/synchro- hub, Refer to Fig. 24
^ Assembling locking collar/synchro- hub, Refer to Fig. 22 and Fig. 23
^ Pressing on, Refer to Fig. 25
27. Sleeve
^ For needle roller bearing
^ Press off with locking collar and 3rd and 4th gear synchro - hub (item 26)
^ Pressing on, Refer to Fig. 26
28. Needle roller bearing
^ For 4th gear
29. 4th gear synchro - ring
^ Checking for wear, Refer to Fig. 9
30. 4th gear
31. Thrust washer
32. Needle roller bearing For output shaft
33. Transmission housing
34. Sleeve
^ For output shaft/pinion shaft needle roller bearing
^ Pressing off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 27
35. 5th gear
36. Dished washer
37. Torx socket head bolt M1O, 80 Nm
^ Fitted portion on bolt head holds dished washer in position
Fig. 1 Pulling out small taper roller bearing outer race
A-Internal extractor 37-46 mm, e.g. Kukko 21/6
B-Counter support, e.g. Kukko 22/2
Fig. 2 Pressing in small taper roller bearing outer race
Fig. 3 Pulling off small taper roller bearing inner race
A-Vice clamps/vice
- Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.
Fig. 4 Pressing on small taper roller bearing inner race
Fig. 5 Pressing off 3rd and 4th gear synchro - hub/locking collar, 2nd, 3rd and 4th gears with transmission housing needle roller bearing sleeve
A-Separating tool 22-115 mm, e.g. Kukko 17/2
B-Hexagon bolt 17 mm AF - M10 x 20
Notes: Support separating tool so that the 1st and 2nd gear locking collar is not pulled off at the same time.
Fig. 6 Pulling off locking collar with synchro - hub via bearing support
A-Two - arm puller, e.g. Kukko 20/10 with 250 mm reach hooks
B-Hexagon bolt 17 mm AF - M10 x 20
Notes: Remove circlip before pulling off individual components.
Fig. 7 Pulling off large taper roller bearing inner race
A-Vice clamps
- Before fitting puller insert a M10 x 20 hexagon bolt in the output shaft drilling.
Fig. 8 Pressing on large taper roller bearing inner race
A-Thrust washer
- Fit thrust washer before pressing on the inner race. The shoulder faces the inner race.
Fig. 9 Checking synchro - ring for wear
- Press synchro - ring onto the gear cone and measure gap "a" with feeler gauge.
Fig. 10 Disassembling and assembling 1st and 2nd gear locking collar and synchro - hub
1. Spring
2. Locking collar
3. Synchro - hub
4. Locking piece
- Slide locking collar over synchro - hub.
The wide shoulder of the synchro - hub (arrow A) and the outer splines of the locking collar (arrow B) face opposite directions after assembly. Recesses for locking pieces on synchro - hub and locking collar must align.
Fig. 11 Assembling 1st and 2nd gear locking collar/synchro - hub -
^ Locking collar is pushed over synchro - hub.
- Insert locking pieces and install springs 1200 off- set. The angled end of the spring must locate in the hollow locking piece.
Fig. 12 Installation position 1st and 2nd gear locking collar/synchro - hub
The locking collar splines (arrow 1) point to splines for 3rd/4th gear synchro - hub - A -.
The wide shoulder of the synchro - hub (arrow 2) then faces toward 1st gear - B -.
Fig. 13 Pressing on 1st and 2nd gear locking collar/synchro - hub
Notes: Before pressing on, place 1st gear synchro - ring on 1st gear.
Fig. 14 Identifying 1st and 2nd gear synchro - rings
- 1st gear synchro - ring with 3 ground - down half teeth (arrow)
- 2nd gear synchro - ring with 3 ground - down half teeth (arrow) or 2 ground - down half teeth
Only the version with 2 ground - down half teeth is available as a replacement part for the 2nd gear synchro - ring.
Fig. 15 Distinguishing 1st and 2nd gear synchro - rings
- 1st gear synchro - ring with no recesses
- 2nd gear synchro - ring with three recesses (arrows)
Fig. 16 Checking 2nd gear synchro - ring for wear
- Press synchro - ring, outer - ring and inner - ring onto gear cone and measure gap "a" with feeler gauge.
Fig. 17 Installation position outer - ring
The lugs (arrows) face toward 1st gear - A -
Fig. 18 Checking inner - ring for wear
- Press inner - ring onto 2nd gear cone and measure gap "a" with a feeler gauge.
Fig. 19 Installation position for synchro - ring (inner - ring) - A -
The lugs (arrow 1) locate in the recesses (arrow 2) in the synchro - ring - B -
Fig. 20 Installation position for 2nd gear
The higher shoulder - A - faces to 1st gear - B -. The recesses in the shoulder (arrows) locate with the lugs of the outer- ring (arrow - Fig. 17).
Fig. 21 Pressing on needle roller bearing sleeve for 3rd gear
Fig. 22 Disassembling and assembling 3rd and 4th gear locking collar and synchro - hub
1. Spring
2. Locking piece
3. Locking collar
4. Synchro - hub
- Slide locking collar over synchro - hub.
The recesses for locking pieces in synchro - hub and locking collar must align.
Fig. 23 Assembling 3rd and 4th gear locking collar/synchro - hub
The locking collar has been pushed over the synchro - hub.
- Insert locking pieces and install springs 120- off - set. The angled end of the spring must locate in the hollow locking piece.
Fig. 24 Installation position for 3rd and 4th gear locking collar/synchro - hub
Chamfer (arrow) faces to 4th gear.
Fig. 25 Pressing on 3rd and 4th gear synchro - hub with locking collar
Fig. 26 Pressing on sleeve for 4th gear needle roller bearing
Fig. 27 Pressing on sleeve for output shaft needle roller bearing