Output Shaft: Service and Repair
5 Speed Manual 02J
Output shaft, disassembling and assembling
Special tools
- VW 407 Punch
- VW 412 Thrust disc
- VW 512 Thrust pad
- VAG 1582 Puller
- VAG 1582/4 Grip piece
- VAG 1582/5 Grip piece
- VW 402 Thrust plate
- 32-111 Thrust piece
- VW 408 A Punch
- VW 407 Punch
- VW 457 Support channels
- 3146 Tube
- VW 429 Thrust ring
- VW 415 A Tube
- VW 447 H Thrust pad
- VW 454 Thrust tube
- VW 455 Thrust tube
- 41-501 Drift sleeve
Note:
The output shaft is disassembled as follows.
- Position separating device under 2nd gear (item 79) and press off as described in Fig, 5.
- Remove circlip (item 15).
- Position two-arm puller under bearing support (item 9) and pull off operating sleeve with 7st and 2nd gear synchronizer hub as described in Fig. 6.
When installing new gears or a new output shaft, consult technical data.
- Both tapered roller bearings must be replaced together as a set.
1 Nut
- 25 Nm (18 ft. lbs.) + 90°
- 4 nuts for bearing support
2 Clutch housing
3 Shim
- For output shaft
4 Small tapered roller bearing outer race
- Removing Fig 1
- Pressing in Fig 2
5 Small tapered roller bearing inner race
- Pulling off refer to Fig 3
- Pressing on refer to Fig 4
6 Output shaft
- Is paired with final drive gear; always replace together as a set
7 Large tapered roller bearing inner race
- Pulling off refer to Fig. 7
- Pressing on refer to Fig. 8
8 O-ring
- Qty. 4
- Place on bearing support bolts
9 Bearing support
- With large tapered roller bearing outer race and bolts
- Only change outer race together with large tapered roller bearing and bearing support
10 Thrust washer
- Shoulder on thrust washer faces tapered roller bearing
11 1st gear
12 Needle roller bearing
- For 1st gear
13 1st: gear synchronizer ring
- Checking for wear refer to Fig. 9
- Identification refer to Fig. 14
14 1st and 2nd gear operating sleeve with synchronizer hub
- Pull off with bearing support after removing circlip (item 15) Fig. 6
- Disassembling refer to Fig. 10
- Assembling operating sleeve/ synchronizer hub refer to Fig. 10 and Fig. 11
- Installation position refer to Fig. 12
- Pressing on refer to Fig. 13
15 Circlip
16 2nd gear synchronizer ring
- Identification refer to Fig. 14
- Checking for wear refer to Fig. 16
- Assemble so that the recesses locate in the operating sleeve (item 14) locking pieces
17 Outer ring
- Insert in synchronizer ring (item 16), installation position refer to Fig. 17
- Replace if scored
18 Synchronizer ring
- (Inner ring)
- Checking for wear refer to Fig. 18
- Check lugs for scoring
- Installation position refer to Fig. 19
19 2nd gear
- Installation position refer to Fig. 20
20 Needle roller bearing
- For 2nd gear
21 Thrust washer
22 Sleeve for 3rd gear needle roller bearing
- Pressing off with 2nd gear refer to Fig. 5
- Pressing on refer to Fig. 21
23 Needle roller bearing
- For 3rd gear
24 3rd gear
25 3rd gear synchronizer ring
- Checking for wear refer to Fig. 9
26 Operating sleeve with 3rd and 4th gear synchronizer hub
- Press off with 2nd gear (item 19) and 3rd gear (item 24) refer to Fig. 5
- Disassembling refer to Fig. 22
- Installation position of operating sleeve/synchronizer hub Fig. 24
- Assembling operating sleeve/ synchronizer hub refer to Fig. 22 and Fig. 23
- Pressing on refer to Fig. 25
27 Sleeve
- For needle roller bearing
- Press off with operating sleeve and 3rd and 4th gear synchronizer hub (item 26) refer to Fig. 5
- Pressing on refer to Fig. 26
28 Needle roller bearing
- For 4th gear
29 4th gear synchronizer ring
- Checking for wear refer to Fig. 9
30 4th gear
31 Thrust washer
32 Needle roller bearing
- For output shaft
33 Transmission housing
34 Sleeve
- For output shaft needle roller bearing
- Pressing off refer to Fig. 5
- Pressing on refer to Fig. 27
35 5th gear
36 Dished washer
37 Torx socket-head bolt
- 80 Nm (59 ft. lbs.)
- M10
- Bolt head holds dished washer in position
Fig. 1 Pulling out small tapered roller bearing outer race
A Internal extractor 37 - 46 mm, e.g. Kukko 21/6
B Counter support, e.g. Kukko 22/2
Fig. 2 Pressing in small tapered roller bearing outer race
Fig. 3 Pulling off small tapered roller bearing inner race
A Vise clamps/vise
- Mount grip piece and tension behind bearing rollers, then turn bearing and retension grip piece.
Fig. 4 Pressing on small tapered roller bearing inner race
Fig. 5 Pressing off 3rd and 4th gear synchronizer hub/ operating sleeve, 2nd, 3rd and 4th gears with transmission housing needle roller bearing sleeve
A Separating device, 22 - 115 mm, e.g. Kukko 17/2
B Bolt,17 mm, M10 x 20
Note:
Support separating device so that the 1st and 2nd gear operating sleeve is not pulled off at the same time.
Fig. 6 Pulling off operating sleeve with synchronizer hub via bearing support
A Two-arm puller, e.g. Kukko 20/10 with 250 mm reach hooks
B Hex head bolt, 17 mm, M10 x 20
Note:
Remove circlip before pulling off individual components.
Fig. 7 Pulling off large tapered roller bearing inner race
A Vise clamps
- Before mounting puller insert an M10 x 20 hex head bolt in output shaft bore.
Fig. 8 Pressing on large tapered roller bearing inner race
A Thrust washer
- Insert thrust washer before pressing on inner race.
Note:
The shoulder faces the inner race.
Fig. 9 Checking synchronizer ring for wear
- Press synchronizer ring onto gear cone and measure gap -a- with feeler gauge.
Fig. 10 Disassembling and assembling list and 2nd gear operating sleeve and synchronizer hub
1 Spring
2 Operating sleeve
3 Synchronizer hub
4 Locking piece
- Slide operating sleeve over synchronizer hub.
Note:
The wide shoulder of the synchronizer hub (arrow -A-) and the outer splines of the operating sleeve (arrow -B-) face opposite directions after assembly
The recesses for the locking pieces on the synchronizer hub and operating sleeve must align.
Fig. 11 Assembling 1st and 2nd gear operating sleeve/ synchronizer hub
- Slide operating sleeve over synchronizer hub.
- Insert locking pieces and install springs 120° offset.
- Angled end of spring must locate in hollow locking piece.
Fig. 12 Installation position of 1st and 2nd gear operating sleeve/synchronizer hub
Note:
- The operating sleeve splines (arrow -1-) point to splines for 3rd/4th gear synchronizer hub -A-.
- The wide shoulder of the synchronizer hub (arrow -2-) then faces toward 1st gear -B-.
Fig. 13 Pressing on 1st and 2nd gear operating sleeve/ synchronizer hub
Note:
Before pressing on, place 1st gear synchronizer ring on 1st gear.
Fig. 14 Identifying 1st and 2nd gear synchronizer rings
Note:
- 1st gear synchronizer ring - qty. 3 ground down half teeth (arrow)
- 2nd gear synchronizer ring - qty 3 ground down half teeth (arrow) or qty. 2 ground down half teeth
- Only the 2nd gear synchronizer ring with qty. 2 ground down half teeth is available as a spare part.
Fig. 15 Identifying 1st and 2nd gear synchronizer rings
Note:
1st gear synchronizer ring - no recesses
2nd gear synchronizer ring - three recesses (arrows)
Fig. 16 Checking 2nd gear synchronizer ring for wear
- Press synchronizer ring, outer-ring and inner-ring onto gear cone and measure gap -a- with feeler gauge.
Fig. 17 Installation position of outer ring
The lugs (arrows) face toward 1st gear -A-
Fig. 18 Checking inner ring for wear
Press inner-ring onto 2nd gear cone and measure gap -a- with feeler gauge.
Fig. 19 Installation position of synchronizer ring (inner ring) -A-
The lugs (arrow -1-) locate in the recesses (arrow -2-) of the synchronizer ring -B-.
Fig. 20 Installation position of 2nd gear
Note:
- The higher shoulder -A- faces toward 1st gear -B-.
- The recesses in the shoulder (arrows) locate with the lugs of the outer-ring (arrow refer to Fig. 17)
Fig. 21 Pressing on needle roller bearing sleeve for 3rd gear
Fig. 22 Disassembling and assembling 3rd and 4th gear operating sleeve and synchronizer hub
1 Spring
2 Locking piece
3 Operating sleeve
4 Synchronizer hub
- Slide operating sleeve over synchronizer hub.
- The recesses for locking pieces in synchronizer hub and operating sleeve must align.
Fig.23 Assembling 3rd and 4th gear operating sleeve/ synchronizer hub
The operating sleeve has been pushed over the synchronizer hub.
- Insert locking pieces and install springs 120° offset
- Angled end of spring must locate in hollow locking piece.
Fig. 24 Installation position of 3rd and 4th gear operating sleeve/synchronizer hub
- Chamfer (arrow) faces toward 4th gear.
Fig. 25 Pressing on 3rd and 4th gear synchronizer hub with operating sleeve
Fig. 26 Pressing on sleeve for 4th gear needle roller bearing
Fig. 27 Pressing on sleeve for output shaft needle roller bearing
