Hollow shaft, disassembling and assembling
Hollow shaft, disassembling and assembling
Install the reverse gear wheel thrust washer
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
• Place the separating device - A - under the thrust washer, not under the circlip.
- Remove the circlip under the thrust washer.
Remove the inner race/tapered roller bearing with the 2nd gear wheel.
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
• When pressing off, make sure that only the gear wheel teeth and not sliding gear splines make contact on separating device - A -. Otherwise gear splining will be damaged.
- Remove the inner race/tapered roller bearing circlip.
Pressing off synchronizer hub for 1st and 2nd gears
- Remove circlip before pressing off.
- Remove the synchronizer hub and 1st gear wheel while positioning the gear wheel in the center of the ring of (VW 470).
Installation position of circlips
- The thickness of the circlips for synchronizer hubs, needle bearings and gear wheels of individual gears should be determined as shown => [ Determining Circlip ] Pinion and Hollow Shaft.
• Circlip - 1 - secures the synchronizer hub 1st and 2nd gear.
Identification: Blue color
• Circlip - 2 - secures inner race/tapered roller bearing.
• The circlip - 3 - secures the reverse gear wheel thrust washer.
• Circlip - 4 - secures the 4th gear wheel
• Circlip - 5 - secures the 6th gear wheel.
- Determine the thickness of the circlips according to the table if necessary.
Installation position of synchronizer rings for 1st and 2nd gear
• If the components are not to be replaced, make sure they are reallocated to their original gear.
- Place inner race - 2 - on sliding gear - 1 -.
- Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
- Synchronizer ring - 4 - installed. Guide tabs - C - through recess - arrow -.
Checking inner race of 1st gear for wear
- Check outer friction surface - arrow - for scoring or signs of wear, replace if necessary.
- Press inner race onto taper of selector gear and measure gap dimension - a - using a feel gauge.
Checking intermediate ring of 1st and 2nd gear for wear
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Press inner race, intermediate ring and synchronizer ring onto the selector gear taper and measure gap dimension - a - using a feel gauge.
Pressing on synchronizer hub for 1st and 2nd gears
• Installation position:
High inner collar faces 2nd gear.
• The notches on the 1st gear synchronizer ring and the notches in the synchronizer hub must line up when installing - arrow -.
Assembly of locking collar/synchronizer hub for 1st and 2nd gear
- Insert pressure pieces - arrows A - into installed synchronizer hubs - 1 -.
- Place sliding sleeve - 2 - over synchronizer hub so that wide tooth spacing of sliding sleeve and synchronizer hub - arrow B - align with each other.
- Install the 1st/2nd gear synchronizer hub circlip.
- Insert the 2nd gear wheel together with needle bearing and synchronizer ring.
- Install the circlip for the inner race/tapered roller bearing onto the hollow shaft.
Pressing on inner race/tapered roller bearing
• The shoulder on the tube (VW 415 A) faces the inner race - arrow -.
Check the 1st and 2nd gear wheels for axial play => [ Checking the gear wheels for axial play ].
Checking the gear wheels for axial play
- Check the axial play between the hollow shaft - 2 - and the 1st gear wheel - 3 - as well as between the 2nd gear wheel - 4 - and the inner race/tapered roller bearing - 5 - using a feeler gauge - 1 -
• The play must be between 0.20 and 0.50 mm.
Install the reverse gear wheel thrust washer.
- Install the circlip - B - on the hollow shaft.
- Install the thrust washer - A - all the way on the circlip.