Pinion Shaft
Pinion Shaft
• Removing and installing gear wheels for 3rd to 6th gear and reverse selector gear is described in chapter on disassembling and assembling transmission. Refer to => [ Transmission ] Transmission.
Special tools, testers and auxiliary items required
• Thrust plate (VW 401)
• Thrust plate (VW 402)
• Press tool (VW 407)
• Thrust disc (VW 412)
• Tube (VW 415 A)
• Tube (VW 519)
• Press tool (40 - 21)
• Thrust piece (2050)
• Thrust pad (3062)
• Press tool (3118)
• Slotted nut wrench (3155)
• Press support-R&I wheel brg's. (3144)
• Assembly tool (3253)
• Tube for wheel bearing (3345)
• Hot air blower (V.A.G 1416)
• Internal puller (Kukko 21/8)
• Splitter (Kukko 17/2)
• Counter-support (Kukko 22/2)
• Feeler gauge
Pulling tapered roller bearing outer race out of transmission housing
- Removing differential. Refer to => [ Differential ] Differential.
- Install thrust piece (2050) with large diameter pointing toward outer race.
- Install threaded spindle and thrust pad of assembly tool (3253) with thrust plate (VW 401) onto transmission housing.
The outer race will be pulled out of transmission housing when nut is tightened.
Heating transmission housing in order to install tapered roller bearing outer race
- Heat transmission housing in area of bearing seat for approximately 15 minutes, to approximately 100 °C, with hot air blower (VAG 1416).
Pressing tapered roller bearing outer race into transmission housing
- Insert outer race only after heating transmission housing and push into position under Workshop press until heat exchange has taken place.
Pulling tapered roller bearing outer race out of bearing housing
A Counter-support, e.g. (Kukko 22/2)
B Internal puller 56 to 70 mm, e.g. (Kukko 21/8)
Pressing tapered roller bearing outer race into bearing housing
Support bearing housing with press support-R&I wheel brg's. (3144) directly below bearing mounting.
- Press in outer race until limit stop.
Pressing off thrust washer for reverse selector gear
A Splitter 22 to 115 mm, e.g. (Kukko 17/2)
• Install splitter - A - below thrust washer, and not below circlip.
- Remove circlip below thrust washer.
Pressing off tapered roller bearing inner race with 2nd speed selector gear
A Splitter 22 to 115 mm, e.g. (Kukko 17/2)
CAUTION!
When pressing off, make sure that only the gear teeth of the selector gear and not the gear shift splines contact the splitter - A -. Otherwise the gear shift splines will be damaged.
- Remove circlip for tapered roller bearing inner race.
Pressing off 1st and 2nd gear synchronizing hub
- Remove circlip before pressing off.
- Press synchronizing hub off with 1st speed selector gear.
Pressing off tapered roller bearing inner race
- Remove circlip before pressing off.
- The outer race of tapered roller bearing - arrow - must be installed prior to pressing off inner race.
Pressing on tapered roller bearing inner race
- Heat inner race to approximately 100 °C and press on.
- Determine thickness of required circlip => [ Determining thickness of circlip ] and install circlip.
Determining thickness of circlip
- Determine thickest circlip that will just fit and install it. For part no.
• The thickness of the circlips for the synchronizing hubs and individual gear wheels must also be determined as shown for the tapered roller bearing.
Overview for installation position of circlips, refer to => [ Installation position of circlips ]
Installation position of circlips
The required circlips for inner races of tapered roller bearings, the synchronizing hubs and individual gear wheels should be selected as shown in => [ Determining thickness of circlip ]
• Circlip - 1 - secures tapered roller bearing inner race.
• Circlip - 2 - secures 1st and 2nd gear synchronizing hub.
Identification: blue color
• Circlip - 3 - secures tapered roller bearing inner race.
• Circlip - 4 - secures thrust washer for reverse selector gear.
• Circlip - 5 - secures 3rd gear wheel.
• Circlip - 6 - secures 6th gear wheel.
- Determine circlips according to table. For part numbers,
Installation position of synchronizing rings for 1st and 2nd gear:
• If components are not being replaced, make sure they are reinstalled on the same gear.
- Install inner ring - 2 - onto selector gear - 1 -.
- Install intermediate ring - 3 -. Lug - B - must be inserted into recess - A -.
- Synchro-ring - 4 - installed. Guide lugs - C - through recess - arrow -.
Checking 1st gear inner ring for wear
- Check outer contact surface - arrow - for scoring or visible traces of wear and replace if necessary.
- Press inner ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.
Checking 1st and 2nd gear intermediate ring for wear
- Check inner contact surface of synchro-ring for scoring or visible traces of wear and replace if necessary.
- Press inner ring, intermediate ring and synchro-ring onto chamfer on selector gear and measure gap - a - using a feeler gauge.
Pressing on 1st and 2nd gear synchronizing hub
• Installation position:
High inside collar faces 2nd gear.
• The lugs of 1st gear synchro-ring and recesses on synchronizing hub must align - arrow - when pressing on.
Assembling 1st and 2nd gear locking collar/synchronizing hub
- Install locking pieces - arrows A - into mounted synchronizing hub - 1 -.
- Install locking collar - 2 - onto synchronizing hub so that the wide splines of locking collar and synchronizing hub - arrow B - coincide.
- Install circlip for 1st and 2nd gear synchronizing hub.
- Install 2nd speed selector gear with needle bearing and synchro-rings.
Pressing on tapered roller bearing inner race
- Install circlip for tapered roller bearing inner race onto pinion shaft.
• Shoulder of tube (VW 415 A) faces inner race - arrow -.
Then check axial play of 1st speed and 2nd speed selector gears, refer to => [ Checking axial play of 1st speed selector gear ] and => [ Checking axial play of 2nd speed selector gear ]
Checking axial play of 1st speed selector gear
- Press 1st speed selector gear - 2 - in direction of - arrow A - as far as stop.
- Measure distance between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge - 1 -.
Example: 2.55 mm
- Press 1st speed selector gear - 2 - in direction of 2nd speed selector gear - 4 -.
- Measure distance again between 1st speed selector gear - 2 - and synchro-ring - 3 - using a feeler gauge - 1 -.
Example: 2.15 mm
• The difference between two measured values must be between 0.20 to 0.50 mm.
Checking axial play of 2nd speed selector gear
- Check axial play between 2nd speed selector gear - 2 - and inner race of tapered roller bearing - 3 - using a feeler gauge - 1 -.
• The play must be 0.20 to 0.50 mm.
Pressing on thrust washer for reverse selector gear
- Install circlip - B - onto output shaft.
- Press on thrust washer - A - until it makes contact with circlip.