Disassembling and Assembling

Special tools and equipment
^ VW222A pilot drift
^ VW295 needle bearing drift
^ VW295A needle-bearing drift
^ VW401 thrust plate and VW402 thrust plate
^ VW407 punch and VW408A punch
^ VW415A tube and VW416B tube
^ VW4471 thrust pad
^ VW771 slide hammer- complete set
^ 30-24 Drift
^ 30-100 Press tube
^ 40-105 Thrust piece
^ 40-202 Press out piece
^ Kukko 17/2 separating tool
^ Kukko 21/1 extractor

Notes:
^ When installing the input shaft or new gears, consult technical data.
^ If parts are exchanged which will affect the position of the ball bearings, the input shaft must be readjusted





1. Circlip
^ Identification color
^ Installation position see Fig. 12
^ Determining thickness adjusting input shaft
2. Ball bearing
^ Removing and installing
3. Circlip
^ Identification color
^ Installation position see Fig. 12, item -2
^ Determining thickness adjusting input shaft Page 3517
4. Transmission - housing
5. Needle roller bearing
^ Secured with bolt see Fig. 1
^ Removing see Fig. 2
^ Installation position see Fig. 3
^ Pressing in see Fig. 4
6. Input shaft
^ With Oiling sleeve
^ Knocking in oiling sleeve
^ Adjusting
7. Needle bearing for 3rd gear
8. 3rd speed sliding gear
9. Spring
^ Insert in 3rd speed sliding gear see Fig. 10
^ Allocation of spring to sliding gear
10. Synchroring for 3rd gear
^ Checking for wear see Fig. 11
11. Circlip
^ Identification color
^ Installation position see Fig. 12
12. Synchrohub for 3rd and 4th gear
^ Shoulder faces to 3rd gear
^ Pressing off see Fig. 9
^ Pressing on see Fig. 14
13. Circlip
^ Identification color
^ Installation position see Fig. 12 item 4
^ If the synchro hub is replaced, redetermine thickness see Fig. 13
14. 3rd and 4th gear locking collar
^ Installation position see Fig. 15
15. Synchroring for 4th gear
^ Checking for wear see Fig. 11
16. Spring
^ Insert in 4th speed sliding gear see Fig. 10
^ Allocation of spring to sliding gear
17. 4th speed sliding gear
18. Needle roller bearing
^ For 4th gear
19. 5th gear wheel
^ Pressing off see Fig. 8
^ Pressing on see Fig. 16
20. Circlip
^ Identification color
^ Installation position see Fig. 12
^ If the 5th gear wheel is replaced, redetermine thickness see Fig. 13
21. Roller sleeve
^ Replace
^ Will be damaged when removing
^ Pulling out see Fig. 5
^ Installation position see Fig. 6
^ Driving in see Fig. 7
22. Sleeve
^ Made of plastic
23. Transmission - cover





Fig. 1 Securing bolt for needle bearing
- Unscrew securing bolt -arrow-.





Fig. 2 Driving-out needle bearing





Fig. 3 Installation position of needle bearing
Dimension "a " from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm

Note: Measure distance from top edge of straight-edge and subtract the width of the straight-edge from the measured distance.





Fig. 4 Pressing in needle bearing
- Install securing bolt and tighten to 25 Nm.





Fig. 5 Pulling out roller sleeve
A - Internal puller 22-28 mm, e.g. Kukko 21/4
- Before fitting internal puller the plastic sleeve inside the roller sleeve must be destroyed.





Fig. 6 Installation position of roller sleeve
^ Distance a = 216 mm





Fig. 7 Driving in roller sleeve





Fig. 8 Pressing off 5th gear wheel
- Remove circlip before pressing off.
A- Separating device 22-115 mm, e.g. Kukko 17/2





Fig. 9 Pressing off synchro-hub for 3rd and 4th gear
- Remove circlip before pressing off.
- Press 3rd gear synchro ring (arrow) towards 3rd gear wheel, then fit separating device -A-.
A- Separating device 22-115 mm, e.g. Kukko 17/2





Fig. 10 Inserting spring in 4th speed sliding gear
The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.





Fig. 11 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
- Calculate average gap.
The average gap must not be less than 0.5 mm.





Fig. 12 Position of circlips
^ The circlips -1- and -2- secure the input shaft ball bearing.
Determine thickness adjusting input shaft.
^ The circlip -3- secures the 3rd and 4th gear synchro-hub.
^ Thickness: 2.00 mm
^ Identification: brown color
^ The circlip -4- secures the 3rd and 4th gear synchro-hub.
^ Determine thickness.
^ Identification: blue color
^ The circlip -5- secures the 5th gear wheel.
Determine thickness.





Fig. 13 Determining thickness of circlip
- Determine the thickest circlip, which will just fit and install it.
- Determine circlip from table. Part No.





The following circlips are available for synchro-hub for 3rd and 4th gear








The following circlips are available for 5th gear wheel





Fig. 14 Pressing on synchro-hub for 3rd and 4th gear





Fig. 15 Installation position of locking collar
Operating sleeves with chamfer -A- as well as operating sleeves with large offset-B- are installed.
Installation position:
^ Chamfer (arrow 1) faces 4th gear
^ Small stepped side (arrow 2) faces 3rd gear
^ Large stepped side (arrow 3) faces 4th gear





Fig. 16 Pressing on 5th gear wheel

WARNING: Wear protective gloves.

- Heat 5th gear wheel to approx. 100°C before pressing on.
Position: wider collar faces towards reverse gear





Fig. 17 Driving in oiling sleeve into input shaft
^ Installation position: flared edge of oil sleeve faces installation tool
^ Installation depth: 3.5 mm under below upper edge





Tightening Torque