Pinion Shaft 1ST to 4TH Gear, Disassembling and Assembling

Pinion shaft 1st to 4th gear, 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
^ VW313 holding fixture
^ VW353 transmission support
^ VW431 thrust pad
^ VW433 thrust pad
^ VW454 thrust tube





Special tools and equipment
^ VW512 thrust pad
^ VW516 tube
^ VW519 sleeve
^ VW771 slide hammer- complete set
^ VW 801 holding fixture
^ 40 105 thrust piece





Special tools and equipment
^ 40 20 sleeve
^ 40 21 sleeve
^ 2050 thrust plate
^ 3161 attachment
^ 3235 press device
^ VAG 1582 taper roller bearing puller





Special tools and equipment
^ VAG 1 58217 attachment to VAG 1582





^ 1 Kukko 21/7 extractor
^ 1 Kukko 2118 extractor
^ 2 Kukko 1812 puller
^ 3 Kukko 1712 separating tool
^ 4 Kukko 2212 support

Notes:
^ When installing new pinions or a new input shaft, technical data 00-3.
^ 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. Oil deflector shield
3. Belleville washer
^ Pulling out, Refer to Fig 1
^ Pressing in, Refer to Fig. 2
4. Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 3
^ Pressing in, Refer to Fig. 4
5. Tapered roller bearing inner race
^ Pressing off, Refer to Fig. 8
^ Pressing on, Refer to Fig 9
6. Pinion shaft
7. Needle bearing
^ For 2nd gear
8. 2nd gear
9. Synchronizer ring
^ inner ring for 2nd gear
^ Check for wear, Refer to Fig. 10
^ heck notches for signs of wear
^ Installed position, Refer to Fig. 12
10. Outer ring for 2nd gear
^ On synchronizer ring (-9-) place on
^ Replace in case of scoring or signs of wear
^ Installed position, Refer to Fig. 12
11. Synchronizer ring 2nd gear
^ Check for wear, Refer to Fig. 11
^ Installed position, Refer to Fig. 12
12. Operating sleeve with synchronizer hub for 1st and 2nd gears
^ After removing securing clip (-13-), press off above bearing support
^ Disassembling, Refer to Fig. 13
^ Assembling operating sleeve/synchronizer hub, Refer to Fig. 13 and Fig. 14
^ Installed position, Refer to Fig. 15
^ Pressing on, Refer to Fig. 16
13. Retaining clip
14. Synchronizer ring 1st gear
^ Check for wear, Refer to Fig. 11
^ Install so that the recesses engage in the dogs of the operating sleeve, Refer to Fig. 12
15. Outer ring for 1st gear
^ Into the synchronizer ring (-14-) insert, installation position, Refer to Fig. 17
^ Replace in case of scoring or signs of wear
16. Synchronizer ring
^ Inner ring for 1st gear
^ Check for wear, Refer to Fig. 10
^ Check notches for signs of wear
^ Installed position, Refer to Fig. 18
17. Needle bearing
^ For 1st gear
18. 1st gear
^ Installed position , Refer to Fig. 19
19. Thrust plates
^ For 1st and 4th gear
^ Insert notches of thrust washer into hole of pinion shaft
20. Washer
^ Holds thrust washers -19- in position on the pinion shaft
21. Needle bearing
^ For 4th gear
22. 4th gear
23. Synchronizer ring 4th gear
^ Checking for wear, Refer to Fig. 22
24. Operating sleeve with synchronizer hub for 3rd and 4th gears After removing securing clip -25- pull off above 4th gear - Fig 6 Disassembling, Refer to Fig. 13 Installation position operating sleeve/synchronizer hub, Refer to Fig. 20 Assembling operating sleeve/synchronizer hub, Refer to Fig. 13 and Fig. 14
^ Pressing on, Refer to Fig. 21
25. Retaining clip
26. Synchronizer ring 3rd gear
^ Check for wear, Refer to Fig. 11
27. Outer ring for 3rd gear
^ Insert into synchronizer ring (-26-): installation position , Refer to Fig. 17
^ Replace in case of scoring or signs of wear
28. Synchronizer ring
^ Inner ring for 3rd gear)
^ Check for wear, Refer to Fig. 10
^ Check notches for signs of wear
^ Installed position, Refer to Fig. 18
29. Needle bearing
^ For 3rd gear
30. 3rd gear
^ Installed position, Refer to Fig. 19
31. Tapered roller bearing inner race
^ Removing - ED
^ Pressing on, Refer to Fig. 23
32. Retaining clip During replacement of tapered roller bearing -31- and the pinion shaft -6- redetermine circlip thickness, Refer to Fig. 24
33. Tapered roller bearing outer race Pulling out , Refer to Fig. 25
^ Pressing in , Refer to Fig. 26
34. Adjustment shim
35. Transmission housing





Fig. 1 Pull Belleville washer - A - out of pinion shaft





Fig. 2 Press Belleville washer into pinion shaft up to stop





Fig. 3 Remove tapered roller bearing outer race
A - support, i.e. Kukko 22/2
B - puller e.g. Kukko 21/8 extractor





Fig. 4 Press tapered roller bearing outer race into clutch housing
- Support clutch housing with 40 20 sleeve directly below bearing support.





Fig. 5 Pull off tapered roller bearing inner race
- Place VW431 thrust pad into pinion shaft and place 40 105 thrust piece on top before installing puller.





Fig. 6 Pull off synchronizer/operating sleeve 3rd and 4th gear via 4th gear.
- First remove circlip.
A - puller e.g. Kukko 18/2 puller
B- separating tool e.g. Kukko 17/2 separating tool





Fig. 7 Press off operating sleeve and synchronizer hub for 1st and 2nd gears
Press off 2nd gear and operating sleeve/synchronizer hub together, after removing circlip.





Fig. 8 Press off tapered roller bearing inner race
A - separating tool 17/2 Kukko 17/2 separating tool





Fig. 9 Pressing on tapered roller bearing inner race





Fig. 10 Checking 1st, 2nd and 3rd gear inner race for wear





- Press inner race onto gear cone and measure gap "a" using feeler gauge.





Fig. 11 Check synchronizer rings 1st, 2nd and 3rd gear for wear





- Press synchronizer ring, outer race and inner race onto gear cone and measure gap "a" using a feeler gauge.





Fig. 12 Installation position of outer race, inner race and synchronizer ring 2nd gear

- Place inner race - A - onto 2nd gear Bent ribs (arrow - 1 -) point to outer race - B -.
- Position outer race - B -
- Align ribs (arrows - 2 -) in notches (arrows - 3 -) of gear.
- Position synchronizer ring - C -
- Align notches (arrows - 4 -) with ribs (arrows - 1 -) of gear -A -.





Fig. 13 Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gear, as well as 3rd and 4th gear
1. Spring
2. Dogs
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 operating sleeve/synchronizer hub for 1st and 2nd gear as well as 3rd and 4th gears.
- Insert dogs and mount springs after rotating 120°. Spring must hook into hollow dog with bent end.
Operating sleeve has been slid over synchronizer hub.





Fig. 15 Installation position of operating sleeve/synchronizer hub for 1st and 2nd gear
The marking (arrow - 1 -) and the narrow collar arrow - 2 -) of synchronizer hug point toward 1st gear.





Fig. 16 Press on operating sleeve/synchronizer hub for 1st and 2nd gear.





Fig. 17 Installation position of outer race for 1st or 3rd gear
The notches (arrows) point toward synchronizer hub/operating sleeve - A -.





Fig. 18 Installation position of synchronizer ring - A - (inner race for 1st or 3rd gear)
The notches (arrows 1) engage in the grooves (arrows 2) of the synchronizer ring - B -.





Fig. 19 Installation position for 1st and 3rd gear
The higher collar - A - points toward 2nd or 4th gear - B -. The cutouts in collar (arrows) engage in the notches of the outer race (arrow - Fig. 17)





Fig. 20 Installation position of operating sleeve/synchronizer hub for 3rd and 4th gear
The wider collar of the synchronizer hub (arrow) points toward 3rd gear.





Fig. 21 Pressing on synchronizer hub with operating sleeve for 3rd and 4th gear





Fig. 22 Checking synchronizer ring for 4th gear for wear





- Press synchronizer ring onto gear cone and measure Gap "a" using feeler gauge





Fig. 23 Pressing on tapered roller bearing inner race





Fig. 24 Determining thickness of circlip

- Determine and install thickest circlip which can still just be installed.








The following securing clips are available:





Fig. 25 Removing tapered roller bearing outer race from clutch housing
A- support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7





Fig. 26 Installing tapered roller bearing outer race in transmission housing
- Insert adjustment shim below outer race.
- Support transmission housing with 2050 thrust pad below bearing support.