Output Shaft For 5th/6th Gear and Reverse Gear
Output Shaft for 5th/6th Gear and Reverse Gear
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Tube (VW 455)
• Thrust Pad (VW 510)
• Tube 42 mm Dia. (VW 516)
• Sleeve (VW 519)
• Thrust Pad (30 - 11)
• Thrust Piece (40 - 105)
• Sleeve (40 - 20)
• Thrust Plate (2050)
• Tube (3296)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment (V.A.G 1582/4)
• Grip (V.A.G 1582/7)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Support Channels (VW 457)
• Holding Fixture (VW 801)
• Kukko 21/7 internal puller
• Separating tool 17/2
• Kukko 22/2 counter-support
Pulling Out Tapered Roller Bearing Outer Race
A Support, for example (Kukko 22/2)
B Internal puller 46..58 mm, for example (Kukko 21/7)
• After pulling off, check the adjustment shim for damage and replace if necessary.
Press the Outer Ring for the Tapered Roller Bearing into the Clutch Housing
- Place the adjustment shim under the outer ring.
- Support clutch housing directly beneath bearing mount using (40 - 20).
Pulling off Inner Race for Tapered Roller Bearing
- Remove circlip.
- Before attaching extractor, place (VW 431) and (40 - 105) on output shaft.
Pressing Off Synchronizer Hub/Locking Collar for 5th and 6th Gear with Selector Gear for 6th Gear
- Before pressing off, remove circlip.
Pressing Off Sleeve - A - over Reverse Gear Selector Gear
- Before pressing off, remove circlip.
Pressing Off Synchronizer Hub for Reverse Gear
- Before pressing off, remove circlip.
A Separating device 22 to 115 mm, for example (Kukko 17/2)
Pulling Off Inner Race for Tapered Roller Bearing
- Before installing puller, set (30 - 11) onto output shaft.
Installation Position of Synchronizer Hub for Reverse Gear
• Stop - arrow A - for reverse gear locking collar points toward output shaft splines - arrow B -.
Pressing on Synchronizer Hub for Reverse Gear
- Then install circlip.
Press on Sleeve - A -
• Installed position: wide collar points toward reverse gear selector gear.
- Then install circlip.
Checking Synchronizer Ring for 5th and 6th Gears for Wear
- Press synchronizer ring onto taper of the gear wheel and measure gap dimension - a - using a feeler gauge.
Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears
- Remove the springs to disassemble - 1 -.
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- To assemble, slide locking collar over the synchronizer hub.
• Installation position: The narrow locking piece recesses in the synchronizer hub align with the recesses in the locking collar.
Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears
• The locking collar is pushed over the synchronizer hub.
- Insert locking pieces and install the springs 120° offset.
• Spring must engage with angled end into hollow engaging piece.
Pressing on Locking Collar/Synchronizer Hub for 5th and 6th Gears
- Then install circlip.
Pressing on Tapered Roller Bearing Inner Race
- Then, determine the circlip and install.
Determining Circlip
- Determine the thickest circlip which can still just be installed and insert it. For the part number, refer to the electronic parts catalog ETKA
The following locking rings are available:
Pressing on Tapered Roller Bearing Inner Race
Pulling Outer Race/Tapered Roller Bearing Out of Transmission Housing
A Support, for example (Kukko 22/2)
B Internal puller 46..58 mm, for example (Kukko 21/7)
Pressing in Tapered Roller Bearing Outer Race into Transmission Housing
- Support the transmission housing with the (2050) under the bearing mount.