Pinion and Hollow Shaft

Pinion and Hollow Shaft

• The removal and installation of 3rd through 6th and reverse gear selector gears is described in Transmission, disassembling and assembling => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence.





Special tools, testers and auxiliary items required

• Pressure Plate (VW 401)

• Pressure Plate (VW 402)

• Punch (VW 407)

• Punch (VW 412)

• Sleeve (VW 415 A)

• Thrust Shell For Pinion Bearing (VW 470)





Special tools, testers and auxiliary items required

• Sleeve (VW 519)

• Seal Driver-Front Wheel Bearing (40 - 21)

• Sleeve (2040)

• Thrust Piece (2050)

• Thrust Pad (3062)

• Thrust Piece (3118)





Special tools, testers and auxiliary items required

• Sleeve (3144)

• Alignment Fixture (3253)

• Tube For Wheel Bearing (3345)

• Heat Gun (V.A.G 1416)

• - 1 - Internal Puller (Kukko 21/8 )

• - 3 - Separating Tool (Kukko 17/2 )

• - 4 - Counter-Support (Kukko 22/2 )

• Feeler Gauge

Removing the Outer Race/Double Tapered Roller Bearing





- Remove differential => [ Differential ] Differential.

- Mount the Thrust Plate (2050) with the large outer diameter facing the outer race.

- Install threaded spindle and thrust bearing of Assembly Tool (3253) with Thrust Plate (VW 401 ) on to transmission housing.

When tightening the nut, the outer race will be pulled out of the transmission housing.

Removing Inner Race/Double Tapered Roller Bearing





- Remove circlip before pressing off.

- To remove the inner race, the outer race must be removed from the double tapered roller bearing - A -.

Installing the Inner Race/Double Tapered Roller Bearing





- Heat inner race to approximately 100 °C and install.

- Determine and install the circlip => [ Determining Circlip ].

Determining Circlip





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

• Circlips for synchronizer hubs and gear wheels of individual gears should be determined as for double tapered roller bearing as shown.

The following circlips are available:





Warming up the Transmission Housing for Installing the Outer Race/Double Tapered Roller Bearing





- Warm up the transmission housing with a hot air gun (V.A.G 1416) near the bearing seat to approximately 100 °C for approximately 15 minutes.

Installing Outer Race/Double Tapered Roller Bearing





- Insert outer race into heated transmission housing and press in with workshop press until temperatures have equalized.

Removing Outer Race/Tapered Roller Bearing from the Bearing Housing





A Support, e.g. ( Kukko 22/2)
B Internal Puller 56 to 70 mm, e.g. (Kukko 21/8)

Installing Outer Race/Tapered Roller Bearing into the Bearing Housing





Support the bearing housing with the Tube (3144 ) directly under the bearing mount.

- Install the outer race all the way.