Output Shaft

Output Shaft

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Thrust Disc (VW 412)

• Tube 60 mm Dia. (VW 415 A)

• Slide Hammer-Complete Set (VW 771)

• Seal Driver (3013)

• Press Support (3118)

• Tube (3296)

• Shop Press (V.A.G 1290A)

• Inductive Heater (VAS 6414)

• - 1 - Internal Puller (Kukko 21/1)

• - 3 - Separating Tool 22 to 115 mm , for example, (Kukko 17/2)

• Removing and installing 1st, 2nd and reverse gears. Refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts ] Shift Fork Group, Input Shaft, 1ST, 2ND and Reverse Gear Output Shafts.

Remove the 3rd and 4th gear wheels, roller bearings and inner race/2nd gear wheel needle bearing from the output shaft.

- Remove the 4th gear wheel locking ring.

Removing the 4th Gear Wheel





• Pressing force may be up to 200 kN (20 t).

• Check the splines on the 4th gear wheel for damage after removing it.

Removing the 3rd Gear Wheel





• Pressing force may be up to 200 kN (20 t).

• Check the splines on the 3rd gear wheel for damage after removing it.

Remove the Roller Bearing with Inner Ring/Needle Bearing - D - for 2nd Gear and Thrust Washer - E - from the Output Shaft





A Separating tool 22 to 115 mm , for example, (Kukko 17/2)

• Place the separating tool - A - underneath the housing - B -.

• Place bearing bracket - C - over roller bearing on output shaft so that the rollers are not pressed out of the bearing cage - B -.

• The roller bearing cage can also get damaged when removing it with a screwdriver. Then mount the separating tool - A - on the inner race.

Install the 3rd and 4th gear wheels, roller bearings and inner race/2nd gear wheel needle bearing on the output shaft.

Installing the Roller Bearing on the Output Shaft





Inner Race/Needle Bearing, 2nd Gear Wheel, Installing





- First fit the thrust washer - A - onto the roller bearing.

- Next, heat the inner race/2nd gear wheel needle bearing up to approximately 100 °C (212 °F), and install all the way up to the stop.


Wear safety gloves.

Heat the 3rd Gear Wheel to a Maximum 150 °C (302 °F) and Install All the Way to the Stop





• Installed position: The high inner collar - arrow - faces the 4th gear.


Wear safety gloves.

• Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

Removing 4th Gear Wheel





• Installed position: The high inner collar - arrow - points to the 3rd gear - A -.


Wear safety gloves.

• Press gear wheel on quickly so that the heat is not transferred right away onto the output shaft.

- Install the 4th gear wheel locking ring.

Flange Shaft Mounting Needle Bearing, Removing from Output Shaft





A Internal puller 12 to 14.5 mm , for example, (Kukko 21/1)

Flange Shaft Mounting Needle Bearing, Installing Flush into the Output Shaft





Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards (3013).