Drive Pinion, Disassembling and Assembling

Drive pinion, disassembling and assembling

Special tools and workshop equipment required
^ VW 401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Thrust tool
^ VW 408 A Pressure tool
^ VW 412 Thrust tool
^ VW 415 A Tube

Special tools and workshop equipment required
^ Crankshaft seal installing tool VW 204 B
^ VW 421 Tube
^ VW 455 Pressing-on sleeve
^ VW 519 Tube
^ VW 771 Multi-purpose tool
^ 2010 Tube

Special tools and workshop equipment required
^ 3005 Thrust plate
^ 3118 Thrust piece
^ 3128 Puller
^ 3301 Assembly equipment
^ 1 - Kukko 21//4 Internal puller
^ 3 - Kukko 17/2 Separating tool

Note:
^ When installing new gears or the final drive set consult technical data
^ Adjustments are required when replacing components marked.

1 - Transmission housing 1)
2 - Shim S3
^ Adjustment overview
3 - Outer race for large tapered roller bearing 1)
^ Pulling out
^ Pressing in
4 - Drive pinion 1)
^ Is mated with ring gear, replace together as a set
^ Adjusting ring gear and drive pinion
5 - Inner race for large tapered roller bearing
^ Always replace
^ Will be damaged during removal
^ Pressing off
^ Pressing on
6 - Circlip Mark
^ Installation position - item 1
^ Re-determine thickness if tapered roller bearing is replaced
7 - Needle bearing for 1th gear
8 - 1st gear sliding gear
9 - Spring
^ Insert in 1st gear sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
10 - Synchro-ring for 1st gear
^ Check for wear
11 - Synchro-hub for 1st and 2nd gear
^ Pressing off
^ Pressing on
12 - Circlip
^ Mark
^ Installation position - item 2
^ Re-determine if the synchro-hub is replaced
13 - Needle bearing for 2nd gear
14 - Locking collar, 1st and 2nd gear
^ Installation position
15 - Synchro-ring for 2nd gear
^ Check for wear
16 - Spring
^ Insert in 2nd gear sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
17 - 2nd gear sliding gear
18 - Circlip
^ Mark
^ Installation position - item 3
19 - 3rd gear wheel Pressing off
^ Shoulder points to 4th gear Pressing on
20 - Circlip
^ Mark
^ Installation position - item 4
^ Re-determine thickness
^ If the 3rd gear wheel is replaced
21 - 4th gear wheel
^ Pressing off
^ Shoulder points to 3rd gear
^ Pressing on
22 - Circlip
^ Mark
^ Installation position - item 5
^ Re-determine thickness if the 4th gear wheel is replaced
23 - Needle bearing
24 - 5th gear sliding gear
25 - Spring
^ Insert in 5th gear sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
26 - Synchro-ring for 5th gear
^ Check for wear
27 - Circlip
^ Mark
^ Installation position - item 6
28 - 5th gear and reverse gear synchro-hub
^ Pressing off Fig. 7
^ Pressing on Fig. 21
29 - Circlip
^ Mark
^ Installation position - item 5
^ If the synchro-hub is replaced re-determine
30 - Needle bearing
^ For reverse gear
31 - Locking collar for 5th and reverse gear
^ Installation position
32 - Reverse gear synchro-ring
^ Check for wear go
33 - Spring
^ Insert in reverse gear sliding gear
^ Allocation of spring to sliding gear
go to Parts Catalog
34 - Reverse gear sliding gear
35 - Inner race for small tapered roller bearing
^ Pressing off
^ Pressing on
36 - Socket
^ To secure small tapered roller bearing outer race Pulling out
^ Need not be fitted after the small tapered roller bearing has been replaced.
37 - Outer race for small tapered roller bearing
^ Pulling out
^ Pressing in
38 - Shim S4
^ Adjustment overview
39 - Pressure plate
40 - Rubber disc
^ Compensates length variations
^ To remove, insert self-tapping screw center and pull out washer on self-tapping screw.
^ Use components according to the transmission code letters via the Parts Catalog.
41 - Transmission cover
^ Apply thin coat of sealing paste AMV 188 001 02 to sealing surfaces

Fig. 1 Pulling out securing bushing for small tapered roller bearing outer race:

A - Internal extractor, e. g. Kukko 21/1, 12... 16 mm

Fig. 2 Pulling out outer race for small tapered roller bearing:

- Screw special tool VW 771/40 into pressure plate
- Install multi-purpose tool VW 771 and pull outer race out via pressure plate.

Fig. 3 Pressing in outer race for small tapered roller bearing:

Fig. 4 Pulling out outer race for large tapered roller bearing:

- Remove differential.
- Place pressure piece of puller 3128 below the outer race.
- Install threaded spindle and pressure bearing of assembly device 3301 with pressure plate VW 401 onto transmission housing.
When tightening bolt the outer race will be pulled out of housing.

Fig. 5 Pressing in outer race for large tapered roller bearing:

The smaller diameter of special tool VW 204 b faces outer race.

Fig. 6 Pressing off inner race for small tapered roller bearing:

^ Press off inner race with reverse gear sliding gear.
A - Separating device 22... 115 mm, e.g. Kukko 17/2

Fig. 7 Pressing off 5th gear and reverse gear synchro-hub:

- Remove circlip before pressing off.
- Press off synchro-hub with 5th gear sliding gear.
A - Separating device 22... 115 mm, e.g. Kukko 17/2

Fig. 8 Pressing off 4th gear wheel:

- Remove circlip before pressing off.

Fig. 9 Pressing off 3rd gear wheel:

- Remove circlip before pressing off.
- Pressing off 3rd gear wheel with 2nd gear sliding gear.
A - Separating device 22... 115 mm, e.g. Kukko 17/2

Fig.10 Pressing off synchro-hub for 1st and 2nd gear:

- Remove circlip before pressing off.
- Press off synchro-hub with 1st gear sliding gear.

Fig.11 Pressing off inner race for large tapered roller bearing:

- Remove circlip before pressing off.
The outer race -A- must be installed to press off the inner race.

Fig. 12 Pressing on inner race for large tapered roller bearing:

Fig. 13 Determining thickness of circlip:

- Determine thickest circlip which will still fit and install it.
The circlips for synchro-hubs and individual gear wheels should also be determined as shown for tapered roller bearing.
Available circlips and part numbers
go to Parts Catalog

Fig. 14 Installation position of circlips:

The circlips for synchro-hubs, needle roller bearings and individual gear wheels should also be determined as shown in.

^ Circlip -1- secures the inner race for tapered roller bearing.

^ Circlip -2- secures the 1st and 2nd gear synchro-hub.

Distinguishing features. Color - blue
^ Circlip -3- secures the needle bearing for 2nd gear sliding gear.

Distinguishing features. Color - blue

^ Circlip -4- secures the 3rd gear wheel.

^ Circlip -5- secures the 4th gear wheel.
^ Circlip -6- secures the needle bearing for 5th gear sliding gear.

Note: Allocate circlip from Parts Catalog.

Distinguishing features. color - brown

^ Circlip -7- secures the synchro-hub for 5th gear and reverse gear.

Distinguishing features. color - blue
- Determine circlips according to table: Part numbers
go to Parts Catalog

Fig. 15 Inserting spring in sliding gear:

The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.

Fig. 16 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-.
- Add measured values and divide by 3.
Calculated value must not be less than 0.5 mm.

Fig. 17 Pressing on synchro-hub for 1st and 2nd gear:

^ Installation position:
High inside collar faces 2nd gear

Fig.18 Installation position of locking collar for 1st and 2nd gear:

^ Installation position:
Chamfered edge -arrow 1 - faces 2nd gear
Shoulder -arrow 2- faces 1st gear

Fig. 19 Pressing on 3rd gear wheel:

^ Installation position:
Groove on gear wheel faces 4th gear

Fig. 20 Pressing on 4th gear wheel:

^ Installation position:
High inside collar faces 3rd gear

Fig. 21 Pressing on 5th gear and reverse gear synchro-hub:

^ Installation position:
High inside collar faces 5th gear

Note: Large inner diameter in special tool 20 10 faces synchro-hub.

Fig. 22 Installation position of locking collar for 5th and reverse gear:

Different types of locking collar are installed: illustration -A-, arrow 1 - with chamfered edge, or illustration -B-, arrow 3- with large shoulder.
^ Make sure locking collar is correct version for reverse gear wheel
^ Installation position:
Chamfered edge -arrow 1 - faces reverse gear
Small shoulder -arrow 2- faces 5th gear
Large shoulder -arrow 3- faces reverse gear