Output Shaft Disassembling and Assembling
5 Speed Manual 02J
Special Tools
- VW 407 Press tool
- VW 412 Press tool
- VW 512 Press disk
- VAG 582 Puller
- VAG 1582/4 Grip piece
- VAG 1582/5 Grip piece
- VW 402 Thrust plate
- 32-111 Thrust piece
- VW 408 A Press tool
- VW 409 Press tool
- VW 457 Support rails
- 3146 Tube
- VW 429 Thrust ring
- VW 415 A Tube
- V\N 447 h Press plate
- VW 454 Press piece
- VW 455 Fitting sleeve
- 41-501 Drift sleeve
Note:
The output shaft is disassembled as follows:
- Position separating device under 2nd gear (item 19) and press off as described in Fig. 5.
- Remove circlip (item 15).
- Position two-arm puller under bearing support (item 9) and pull off locking collar with 1st 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.) and then turn 90° further.
- 4 nuts for bearing support
2. Clutch housing
3. Shim
- For output shaft
- Adjustment overview.
4. Small tapered roller bearing outer race
- Removing refer to Fig. 1
- Pressing in refer to Fig. 2
5. Small tapered roller bearing inner race
- Pulling off refer to Fig. 3
- Pressing on refer to Fig. 4
6. Output shaft
- Paired with final drive gear, always replace together as a set
- Adjusting
7. Large tapered roller bearing inner race
- Pulling off refer to Fig. 7
- Pressing on refer to Fig. 8
8. O-ring
- Install O-rings (Qty. 4) on bearing support bolts
9. Bearing support
- With large tapered roller bearing outer race and bolts
- Only replace 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 locking collar with synchronizer hub
- Pull off with bearing support after removing the circlip (item 15) refer to Fig. 6
- Disassembling refer to Fig. 10
- Assembling locking collar/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 locking collar (item 14) locking pieces
17. Outer ring
- Insert in the 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 2rd 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. Locking collar with 3rd and 4th gear synchronizer hub
- Press off with 2nd clear (item 19) and 3rd gear (item 24) refer to Fig. 5
- Disassembling refer to Fig. 22
- Installation position of locking collar/synchronizer hub refer to Fig. 24
- Assembling locking collar/synchronizer hub refer to Fig. 22 and Fig. 23
- Pressing on refer to Fig. 25
27. Sleeve
- For needle roller bearing
- Press off with locking collar 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
- Removing and installing
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
- Removing and installing
36. Dished washer Installation position
37. Torx socket head bolt M10, 80 Nm
- Fitted portion on bolt head holds saucer spring 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 gripping piece and tension behind bearing rollers, then turn bearing and re-tension gripping piece.
Fig. 4 Pressing on small tapered roller bearing inner race
Fig. 5 Pressing off 3rd and 4th gear synchronizer-hub/locking collar, 2nd, 3rd and 4th gears with transmission housing needle roller bearing sleeve
A-Separating device 22 - 115 mm, e.g. Kukko 1712
B-Bolt 17 mm - M10 x 20
Note:
- Support separating appliance so that the 1st and 2nd gear locking collar is not pulled off at the same time.
Fig. 6 Pulling off locking collar with synchronizer hub via bearing support
A-Two-arm puller, e.g. Kukko 20/10 with 250 mm reach hooks
B-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 M 10 x 20 hex 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 the gear wheel cone and measure gap -a- with feeler gauge.
Fig. 10 Disassembling and assembling 1st and 2nd gear locking collar and synchronizer hub
1. Spring
2. Locking collar
3. Synchronizer hub
4. Locking piece
- Slide locking collar over synchronizer hub.
- The wide shoulder of the synchronizer hub (arrow -A-) and the outer splines of the locking collar (arrow -B-) face opposite directions after assembly.
- Recesses for locking pieces on synchronizer hub and locking collar must align.
Fig. 11 Assembling 1st and 2nd gear locking collar/synchronizer hub
- Push locking collar over synchronizer-hub.
- Insert locking pieces and install springs 120° offset.
- The angled end of the spring must locate in the hollow locking piece.
Fig. 12 Installation position of 1st and 2nd gear locking collar/synchronizer hub
The locking collar splines (arrow -l-) point to splines for3rd/4th gear synchronizer hub -A-.
The wide shoulder of the synchronizer hub (arrow-2-) then faces to 1st gear -B-.
Fig. 13 Pressing on 1st and 2nd gear locking collar/synchronizer hub
Note:
- Place 1st gear synchronizer ring on 1st gear before pressing on.
Fig. 14 Identifying 1st and 2nd gear synchronizer rings
- 1st gear synchronizer ring-three ground down half teeth (arrow)
- 2nd gear synchronizer ring-two or three ground down half teeth (arrow)
Only the 2nd gear synchronizer ring with two ground down half teeth is available as a spare part.
Fig. 15 Distinguishing 1st and 2nd gear synchronizer rings
- 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 a feeler gauge.
Fig. 19 Installation position synchronizer ring (inner ring) -A-
The lugs (arrow -1-) locate in the recesses (arrow-2-) in the synchronizer ring -B-.
Fig. 20 Installation position 2nd gear
- The higher shoulder -A- faces to 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 locking collar and synchronizer hub
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide locking collar over synchronizer hub.
- Recesses for locking pieces in synchronizer hub and locking collar must align.
Fig. 23 Assembling 3rd and 4th gear locking collar/synchronizer hub
Locking collar has been pushed over synchronizer hub in illustration,
- Insert locking pieces and install springs 120° offset.
- Angled end of the spring must locate in the hollow locking piece.
Fig. 24 Installation position 3rd and 4th gear locking collar/synchronizer hub
Chamfer (arrow) faces toward 4th gear.
Fig. 25 Pressing on 3rd and 4th gear synchronizer hub with locking collar
Fig. 26 Pressing on sleeve for 4th gear needle roller bearing
Fig. 27 Pressing on sleeve for output shaft needle roller bearing
Modified 1st gear synchronization from transmission build date 02 05 00
The following components have been added or modified:
- A- Inner ring
- B- Outer ring
- C- Synchro-ring
with additional recesses At- for the lugs -1- of inner ring -A-.
- 1st gear
with additional recesses -3- for the lugs -2- of outer ring -B-.
Note:
- For the 2nd gear the same inner ring, outer ring and synchro ring are installed.
- If the components are not replaced, ensure they are reallocated to the original gear.
Installation position of inner ring, outer ring and synchro-ring 1st gear:
- Place inner ring -A- on 1st gear.
Angled lugs (arrow 1) point towards outer ring -B
- Install outer ring -B-.
Lugs (arrow 2) engage in gear recesses (arrow
- Install synchro-ring -C-.
The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.
Check inner ring 1st gear for wear
- Press inner ring onto gear cone and measure gap "a" with a feeler gauge.
Check synchro-ring 1st gear and outer ring for wear
- Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.
Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub
1. Spring
2. Locking collar
3. Synchro-hub
4. Locking piece
With introduction of the modified 1st gear synchronization the shoulder has the same width on both sides of synchro-hub.
The shoulder has a chamfer on one side (arrow B).
After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same direction.
Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align.
Installation position of locking collar/synchro hub 1st and 2nd gear
The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-.
- Remove 1st gear synchro-hub as described and install again.