Bearing Plate, Servicing

Bearing plate, servicing, 01E, 6 Spd. M/T AWD

Special tools and equipment:

^ VW 408 A Press tool
^ 10-15 Guide pins
^ 30-504 Press tool
^ 1 - Kukko 21/3 Internal puller
^ 4 - Kukko 22/1 Counter support
^ Depth gauge





1 - Bearing plate
^ Re-determine shim S4 when replacing

2 - Outer race/small taper roller bearing for drive pinion
^ Driving out, go to Fig. 15
^ Pressing in, go to Fig. 16
^ Re-determine shim S4 when replacing

3 - Shim S4
^ Adjustment overview
^ Re-determining thickness

4 - Cylinder roller bearing for input shaft
^ Pressing out go to Fig. 5
^ Pressing in go to Fig. 6
^ Measuring insertion depth go to Fig. 7





5 - Ball sleeves
^ 4 pieces
^ Removing and driving in go to Fig. 1
For follower for reverse gear:
^ Pulling out go to Fig. 3
^ Tapping in go to Fig. 4

6 - Bolt, 35 Nm
^ For relay lever

7 - Dowel pin (7 x 28)
^ Drive in and drive out with drift

8 - Reverse idler gear
^ For reverse gear

9 - Reverse gear synchro-ring
^ With locking pins
^ Checking for wear go to Fig. 2
^ Installation position: Position flat on synchro-ring circumference to face 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 - Reverse idler gear axle
12 - Retaining plate
^ Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate

13 - Spring clasp
^ 14 - Bolt, 25 Nm
^ Self-locking
^ Always replace





15 - Relay lever for reverse gear
16 - Follower for reverse gear
^ Pulling out ball sleeve go to Fig. 3
^ Driving in ball sleeve go to Fig. 4

17 - Selector rod for 5th and 6th gear
^ Replace only together with follower, Item 6





Fig. 1 Driving out and driving in ball sleeves for selector rods
Install ball sleeve with the inscribed side (thicker metal) facing the drift.
^ Insertion depth a = 2.5 mm





Fig. 2 Checking synchro-ring for wear
- Press synchro-ring onto reverse idler gear cone and measure gap a with feeler gauge.
^ Dimension, new: 0.75 to 2.3 mm
^ Wear limit: 0.2 mm





Fig. 3 Pulling ball sleeve out of follower for reverse gear
A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2





Fig. 4 Driving ball sleeve flush into follower for reverse gear
Install ball sleeve with the inscribed side (thicker metal) facing the drift.





Fig. 5 Pressing cylinder roller bearing for input shaft out of bearing plate





Fig. 6 Pressing cylinder roller bearing for input shaft into bearing plate
- Measuring insertion depth go to Fig. 7





Fig. 7 Measuring insertion depth of cylinder roller bearing for input shaft
Dimension a = 7 mm