Drive Pinion Up to Transmission Manufacture Date 22 06 3, Disassembling and Assembling
Drive pinion up to transmission manufacture date 22 06 3, disassembling and assembling, 012/01W, 5 SPD. M/T
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 VW 415 A
^ Pulling device for crankshaft oil seal VW 204 B
^ Tube 28mm Dia. 1 00mm VW 421
^ Thrust Tube VW 455
^ Sleeve VW 519
^ Slide Hammer-Complete Set VW 771
^ Sleeve 2010
^ Thrust Pad 3005
^ Press Support 3118
^ Bushing Puller 3128
^ Assembly Tool 3301
^ 1 - Internal extractor Kukko 21/4
^ 3 - Separating tool Kukko 17/2
Note:
^ As of transmission manufacture date 23 06 3 a new synchronization for 1st and 2nd gear as well as for 5th and reverse gear is applied. Disassembling and assembling drive pinion as of transmission manufacture date 23 06 3.
^ When installing new gears or gear set, observe technical data.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing
2. Adjustment shim "S3"
3. Large tapered roller bearing outer race
^ Pulling out
^ Pressing in
4. Drive pinion
^ Matched to ring gear, always replace together as a set
^ Adjust drive pinion and ring gear
^ Reinforcement measures as of transmission manufacture date 17 08 8
5. Large tapered roller bearing inner race
^ Replace
^ Damaged when removed
^ Pressing off
^ Pressing on
6. Circlip
^ Identification
^ Installed position - item 1 -
^ Re-determining thickness when replacing tapered roller bearing
7. Needle bearing for 1st gear
8. 1st gear
9. Spring
^ Inserting in 4th gear
10. Synchronizer ring for 1st gear
^ Checking for wear
11. Synchronizer hub for 1st and 2nd gears
^ Pressing off
^ Pressing on
^ Higher inner collar faces 2nd gear
12. Circlip
^ Identification
^ Installed position - item 2 -
^ Re-determining thickness when replacing synchronizer body
13. Needle bearing 2nd gear
14. Operating sleeve for 1st and 2nd gear
^ Installed position
15. Synchronizer ring for 2nd gear
^ Checking for wear
16. Spring
^ Inserting in 2nd gear
^ Application of spring to gear Electronic Parts Catalog (ETKA)
17. 2nd gear
18. Circlip
^ Identification
^ Installed position - item 3 -
19. 3rd gear
^ Pressing off
^ Groove faces 4th gear
^ Pressing on
20. Circlip
^ Identification
^ Installed position - item 4 -
^ If 3rd gear is replaced, re-determine thickness of circlip
21. 4th gear
^ Pressing off
^ Shoulder faces 3rd gear
^ Pressing on
^ Reinforcement measures as of transmission manufacture date 17 08 8
22. Circlip
^ Identification
^ Installed position - item 5 -
^ If 4th gear is replaced, re-determine thickness of circlip
^ Reinforcement measures as of transmission manufacture date 17 08 8
23. Needle bearing
^ Reinforcement measures as of transmission manufacture date 17 08 8
24. 5th gear
^ Reinforcement measures as of transmission manufacture date 17 08 8
25. Spring
^ Inserting in 5th gear
26. Synchronizer ring for 5th gear
^ Checking for wear
27. Circlip
^ Identification
^ Installed position - item 6 -
28. Synchronizer hub for 5th and reverse gear
^ Pressing off
^ Pressing on
^ Higher inner collar faces 5th gear
29. Circlip
^ Identification
^ Installed position - item 5 -
^ Re-determining thickness when replacing synchronizer body
30. Needle bearing
^ For reverse gear
31. Operating sleeve for 5th and reverse gear
^ Installed position
32. Synchronizer ring reverse gear
^ Checking for wear
33. Spring
^ Inserting in reverse gear
34. Gear wheel for reverse gear
35. Small tapered roller bearing inner race
^ Pressing off
^ Pressing on
36. Socket
^ Secures small tapered roller bearing outer race
^ Pulling out
^ Does not need to be reinstalled after small tapered roller bearing was replaced
37. Small tapered roller bearing outer race
^ Pulling out
^ Pressing in
38. Adjustment shim "S4"
39. Thrust plate
^ Various thicknesses for transmissions made out of aluminum and magnesium
40. Rubber washer
^ Compensated length variations
^ When removing, screw in sheet metal screw in center and remove washer at sheet metal screw.
^ Various thicknesses for transmissions made out of aluminum and magnesium
41. Transmission cover
^ Made out of aluminum, may only be installed with transmission housing made out of aluminum
^ Made out of magnesium, may only be installed with transmission housing made out of magnesium
^ Note identification,
^ Coat sealing surfaces with a thin layer of sealant AMV 188 001 02
Pulling off securing bushing for small tapered roller bearing outer race
A - Internal puller 12 to 16 mm, e.g. Kukko 21/1
Pulling off outer race of small tapered roller bearing
^ Install special tool VW 771/40 into thrust plate.
^ Install Slide Hammer-Complete Set VW 771 and pull out outer race over thrust plate.
Pressing in outer race for small tapered roller bearing
Pulling out double tapered roller bearing outer race
^ Place pressure piece from Bushing Puller 3128 under outer race.
^ Install threaded spindle and thrust bearing of Assembly Tool 3301 with Thrust Plate VW 401 onto transmission housing.
When the bolt is tightened, the outer race will be pulled out of the housing.
Pressing in double tapered roller bearing outer race
The smaller diameter of the arbor VW 204 B faces outer race.
Pressing off tapered roller bearing inner race
^ Press off inner race together with reverse gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing on tapered roller bearing inner race
Press off synchronizer hub for 5th and reverse gear
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 5th gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off 4th gear
^ Remove circlip before pressing off.
Pressing off 3rd gear
^ Remove circlip before pressing off.
^ Press off 3rd gear with 2nd gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off synchronizer hub for 1st and 2nd gears
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 1st gear.
Pressing off double tapered roller bearing inner race
^ Remove circlip before pressing off.
^ Outer race - A - must be installed to press off inner race.
Pressing on double tapered roller bearing inner race
Determining circlip
^ Determine thickest circlip which can still just be installed - and insert.
^ Circlips for synchronizer hubs and individual gears should be determined as for tapered roller bearing as shown. Circlips available and part numbers Electronic Parts Catalog (ETKA).
Installed position of circlips
^ Circlips for synchronizer hubs, needle bearings and gear wheels for individual gears must also be determined as shown.
Circlip - 1 - secures inner race of tapered roller bearing.
Circlip - 2 - secures the synchronizer hub for 1st and 2nd gear.
Distinguishing characteristic: blue color
Circlip - 3 - secures needle bearing for 2nd gear.
Distinguishing characteristic: blue color
Circlip - 4 - secures 3rd gear.
Circlip - 5 - secures 4th gear.
Circlip - 6 - secures needle bearing for 5th gear.
Distinguishing characteristic: brown color
Circlip - 7 - secures synchronizer hub for 5th and reverse gear.
Distinguishing characteristic: blue color
Determine circlips according to table.
Inserting spring into gear
The bent end of spring - arrow - must be hooked into hole of shift gear.
Checking synchronizer for wear
^ Press synchronizer ring into operating sleeve and measure gap dimension - a - using a feeler gauge at positions - A -, - B -, and - C -.
^ Add measured values and divide total by three to calculate average.
Determined value must not be more than 0.5 mm.
Press on synchronizer hub for 1st and 2nd gears
^ Installed position:
Higher inner collar faces 2nd gear
Installation position of operating sleeve for 1st and 2nd gear
^ Installed position:
Chamfer - arrow 1 - faces 2nd gear.
Chamfer - arrow 2 - faces 1st gear.
Pressing on 3rd gear
^ Installed position: The groove on the gear faces 4th gear.
Pressing on 4th gear
^ Installed position: Higher inner collar faces 3rd gear
Press on synchronizer hub for 5th and reverse gear
^ Installed position: Higher inner collar faces 5th gear
Note:
^ The larger inner diameter of Sleeve 20 10 points toward synchronizer hub.
Installation position of operating sleeve for 5th and reverse gear
Operating sleeves with chamfer - A arrow 1 - as well as operating sleeves with large offset - B arrow 3 - are installed.
^ Note allocation of operating sleeve to reverse idler gear
^ Installed position:
Chamfer - arrow 1 - faces reverse gear.
Small offset - arrow 2 - faces 5th gear.
Large offset - arrow 3 - faces reverse gear.
Allocation of operating sleeve to reverse idler gear
Differentiation of thrust plates
Differentiation of rubber washers
