Bearing Plate, Servicing
Bearing plate, servicing - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items required:
^ Internal puller 18.5-23.5 mm (e.g. Kukko 21/3)
^ 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, re-determine shim "S4"
2 - Outer race for tapered roller bearing for drive pinion
^ If replacing, re-determine shim "S4"
3 - Shim "S4"
4 - Cylinder roller bearing for input shaft
^ Measure insertion depth
5 - Ball sleeve
^ For selector rods
^ Replace
6 - Bolt, 35 Nm
^ For relay lever
7 - Dowel pin (7 x 28)
^ Press in flush
8 - Sliding gear for reverse gear
9 - Synchro-ring for reverse gear
^ With locking pins
^ Check for wear
^ Installation position: flat on circumference of synchro-ring faces towards input shaft
10 - Spring
^ Installation position: hook single angled end into recess on synchro-ring. Turn double angled end anti-clockwise 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
13 - Spring clasp
14 - Bolt, 25 Nm
^ Self-locking
^ Replace
15 - Relay lever for reverse gear
16 - Follower for reverse gear
^ Pull out ball sleeve
^ Drive in ball sleeve
17 - Selector rod for 5th and 6th gear
^ Replace only complete with follower
^ Insertion depth a = 2.5 mm
Check 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
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
Drive ball sleeve flush into follower for reverse gear
Press cylinder roller bearing for input shaft out of bearing plate
Press cylinder roller bearing for input shaft into bearing plate
Insertion depth depends on serial number of transmission.
Measure insertion depth.
Measure insertion depth of cylinder roller bearing for input shaft
a = 7mm