5TH/6TH and Reverse Gear Pinion Shaft
5th/6th and reverse gear pinion shaft, disassembling and assembling
Special tools and equipment
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW408A punch
^ VW412 thrust disc
^ VW41 5A tube
Special tools and equipment
^ VW 309 holding fixture
^ VW353 transmission support
^ VW433 thrust pad
^ VW454 thrust tube
^ VW 457 support channels
^ VW 801 holding fixture
Special tools and equipment
^ VW431 thrust pad
^ VW455 thrust tube
^ VW510 thrust pad
^ VW516 tube
^ VW519 sleeve
^ 30 11 thrust piece
Special tools and equipment
^ 40 105 thrust piece
^ 40 20 sleeve
^ 2050 thrust plate
^ 3235 press device
^ 3296 tube
Special tools and equipment
^ VAG 1582 taper roller bearing puller
^ VAG1582/4 attachment to VAG1582
^ VAG1582/7 attachment to VAG1582
^ 1 Kukko 21/7 extractor
^ 3 Kukko 17/2 separating tool
^ 4 Kukko 22/2 support
Notes:
^ When installing new pinions or a new input shaft, consult technical data.
^ If a pinion shaft or tapered roller bearing is being replaced, an adjustment of the pinion shaft must be carried out.
1. Clutch housing
2. Washer
^ Always 0.65 mm thickness
3. Tapered roller bearing outer race
^ Pulling outs, Refer to Fig. 1
^ Pressing in Fig 2
4. Tapered roller bearing inner race
^ Removing, Refer to Fig. 8
^ Pressing on, Refer to Fig. 18
5. Pinion shaft
6. Synchronizer hub for reverse gear
^ Pressing off , Refer to Fig. 7
^ Installed position
^ Pressing on, Refer to Fig. 10
7. Retaining clip
8. Operating sleeve for reverse gear
^ With synchronizer ring
9. Needle bearing
^ For reverse gear
10. Reverse gear
11. Sleeve
^ Press off via reverse gear, Refer to Fig. 6
^ Installation position: wide collar of sleeve points toward reverse gear - Pressing on, Refer to Fig. 11
12. Retaining clip
13. Needle bearing
^ For 6th gear
^ Not installed on 5 gear manual transmission
14. 6th gear
^ Not installed on 5 gear manual transmission
15. Synchronizer ring 6th gear
^ Not installed on 5 gear manual transmission
^ Check for wear - Fig. 12
16. Spacer sleeve
^ For 5th gear manual transmission
^ After removing securing clip (-18-) with operating sleeve/synchronizer hub 5th gear, pressing off, Refer to Fig. 5
^ With operating sleeve/synchronizer hub 5th gear, pressing off, Refer to Fig. 16 Pressing on with operating sleeve/synchronizer hub 5th gear, Refer to Fig. 17
17. Operating sleeve with synchronizer hub for 5th and 6th gears After removing securing clip (-18-) press off with 6th gear, Refer to Fig. 4, or press off with spacer sleeve on 5 speed manual transmissions
^ Disassembling, Refer to Fig. 13
^ Assembling operating sleeve/synchronizer hub Fig. 13 and Fig. 14
^ Pressing on with 6 speed manual transmission, Refer to Fig. 15
^ Pressing on with 5 speed manual transmission, Refer to Fig. 17
18. Retaining clip
19. Needle bearing
^ For 5th gear
20. Synchronizer ring 5th gear
^ Check for wear , Refer to Fig. 12
21. 5th gear
22. Tapered roller bearing inner race
^ Removing, Refer to Fig. 3
^ Pressing on, Refer to Fig. 18
23. Retaining clip
^ During replacement of tapered roller bearing -22- and the pinion shaft -5- redetermine, Refer to Fig. 19
24. Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 21
^ Pressing in, Refer to Fig. 22
25. Adjustment shim
26. Transmission housing
27. Spring
^ Installed position, Refer to Fig. 14
28. Sliding sleeve
29. Synchronizer hub
30. Dogs (3 pieces)
^ Installed position, Refer to Fig. 13
Fig. 1 Pulling out tapered roller bearings outer race
A- support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7
Notes: After removing, check shim for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into clutch housing
- Place shim under outer ring.
- Support clutch housing with 40 20 sleeve directly below bearing support.
Fig. 3 Pulling off tapered roller bearing inner ring
- Place 431 attachment piece and 10 105 thrust piece onto pinion shaft before installing puller
Fig. 4 Pulling off synchronizer hub/operating sleeve 5th and 6th gear with 6 gear
Fig. 5 Pressing off synchronizer hub/operating sleeve 5th gear with spacer sleeve
Fig. 6 Pressing off sleeve - A - via reverse gear
Fig. 7 Pressing off synchronizer hub for reverse gear
A- separating tool e.g. Kukko 17/2 separating tool
Fig. 8 Pulling off tapered roller bearing inner ring
- Place 30 11 thrust pad onto pinion shaft before installing puller.
Fig. 9 Installation position of synchronizer hub for reverse gear
The stop (arrow - A -) for operating sleeve for reverse gear points toward teeth of pinion shaft (arrow).
Fig. 10 Pressing on synchronizer hub for reverse gear
Fig. 11 Press on sleeve - A -
Installation position: Wide collar points toward reverse gear.
Fig. 12 Check synchronizer ring 5th and 6th gear for wear.
- Press synchronizer ring onto gear cone and measure Gap "a" using feeler gauge
Fig. 13 Disassemble and assemble operating sleeve and synchronizer hub for 5th and 6th gear
1. Spring
2. Dog
3. Sliding sleeve
4. Synchronizer hub
- Slide operating sleeve over synchronizer hub
Notches for dogs at synchronizer hub and operating sleeve must lie on top of one another.
Fig. 14 Assembling of operating sleeve/synchronizer hub for 5th and 6th gear
Operating sleeve has been slid over synchronizer hub
- Insert dogs and mount springs after rotating 1200 Spring must hook into hollow dog with bent end.
Fig. 15 Pressing on operating sleeve with synchronizer hub for 5th and 6th gears
Fig. 16 Position spacer sleeve to operating sleeve/synchronizer hub 5th gear
Notches (arrow 1) of spacer sleeve and cutouts of synchronizer hub (arrow 2) must line up on top of each other.
Locking piece (arrow 3) must lie against collar of spacer sleeve.
Fig. 17 Pressing on operating sleeve/synchronizer hub 5th gear using spacer sleeve
Fig. 18 Pressing on tapered roller bearing inner race
Fig. 19 Determine shim size
- Determine and install thickest circlip which can still just be installed.
The following securing clips are available
Fig. 20 Pressing on tapered roller bearing inner race
Fig. 21 Removing tapered roller bearing outer race from clutch housing
A- support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7
Fig. 22 Installing tapered roller bearing outer race in transmission housing
- Support transmission housing with 2050 thrust pad below bearing support.