Bearing Housing, Servicing

Bearing housing, servicing, 02X, 6-Speed Four-Wheel Drive M/T





Special tools, testers and auxiliary items required
^ Thrust plate VW 402
^ Punch VW 408 A
^ Thrust disc VW 412
^ Thrust tube VW 454
^ Installing sleeve VW 455
^ Tube VW 516





Special tools, testers and auxiliary items required
^ Guide pin 10 - 15
^ Thrust pad 3074
^ - 1 - Internal puller Kukko 21/2
^ - 4 - Counter-support Kukko 22/1
^ Drift T40085





1 - Bearing housing
^ Re-determine shim "S4" when replacing

2 - Outer race
^ For needle roller bearing on input shaft
^ Driving out
^ Pressing in

3 - Shim "S4"
^ Re-determine when replacing bearing housing

4 - Tapered roller bearing outer race
^ For pinion shaft/hollow shaft

5 - Selector rod for 1st and 2nd gear
^ Only replace together with selector fork for 1st and 2nd gear (secured together by means of a pin)

6 - Reverse gear selector rod

7 - Ball sleeve
^ (Front) for reverse gear selector rod
^ Pulling out
^ Pressing in

8 - Ball sleeve
^ (Rear) for reverse gear selector rod
^ Pulling out
^ Pressing in

9 - Selector rod for 3rd and 4th gear

10 - Selector rod for 5th and 6th gear
^ Remove burrs and scoring after removing from bearing housing

11 - Ball sleeve
^ For selector rod for 5th and 6th gear
^ Pull out with internal puller Kukko 21/2
^ Drive in until flush using guide pin 10 - 15

12 - Locking bushing
^ For selector rod for 3rd and 4th gear

13 - Locking bushing
^ For selector rod for 5th and 6th gear

14 - Ball sleeve
^ For selector rod for 3rd and 4th gear
^ Pull out with internal puller Kukko 21/2

Driving in





Driving outer race for needle roller bearing out of bearing housing
- Clamp bearing housing in vise, using jaw protectors - C -.
- Drive out outer race - A - using drift - B - by alternately applying drift to the bearing housing recesses located opposite each other - arrow -.





Pressing outer race for needle roller bearing into bearing housing until limit stop





Pulling front ball sleeve out of reverse gear selector rod
A - Counter-support, e.g. Kukko 22/1
B - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2





Pressing front ball sleeve into reverse gear selector rod until limit stop.
Install ball sleeve - arrow - so that side with lettering (thicker metal) faces guide pin 10 15.





Pulling out rear ball sleeve for reverse gear selector rod
- Clamp actuating arm of selector rod in vise, using jaw protectors - C -.
- Install thrust tube VW 454 and installing sleeve VW 455 onto selector rod.
A - Counter-support, e.g. Kukko 22/1
B - Internal puller 14.5 to 18.5 mm, e.g. Kukko 21/2





Pressing in rear ball sleeve - A - for reverse gear selector rod





Driving in ball sleeve for selector rod for 3rd and 4th gear

Install ball sleeve so that side with lettering (thicker metal) faces guide pin 10 - 15.

Dimension for pressing in - a - 2.5 mm





Removing and installing locking bushing for selector rod

Remove relevant selector rod (for 3rd and 4th gear or for 5th and 6th gear).

Bolt bearing housing - B - with transmission cover - A - onto transmission housing prior to driving out and driving in locking bushings - C -.
- Drive out old locking bushing inward into bearing housing.
- Drive in new locking bushing until flush.