Pinion Shaft and Hollow Shaft, Disassembling and Assembling (As of Transmission Manufacture Date 23 06 3)
Pinion shaft and hollow shaft, disassembling and assembling (as of transmission manufacture date 23 06 3), 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 407
^ Punch VW 411
^ Punch VW 412
^ Tube VW 415 A
Special tools, testers and auxiliary items required:
^ Tube VW 416 B
^ Tube VW 418 A
^ Thrust ring VW 429
^ Thrust pad VW 447 i
^ Thrust piece VW 454
^ Tube VW 519
Special tools, testers and auxiliary items required:
^ Slide Hammer-Complete Set VW771
^ Sleeve 40 - 103
^ Tube 2010
^ Thrust pad 3062
^ Bushing Puller 3128
^ Separating device Kukko 17/2
^ Internal puller Kukko 21/1
Note:
^ As of transmission manufacture date 23 06 3, a new 3-stage synchronization for 1st gear and a 2-stage synchronization for 2nd gear, and synchronizer rings with enlarged friction cone and reduced gear splining for 5th gear and reverse gear have been implemented. Sliding gears, sliding sleeves and synchronization hubs were adapted accordingly and cannot be installed interchanged with synchronization parts of the earlier construction type.
^ When installing new gear wheels or gear set, note Technical Data.
^ Adjustments are required when replacing components marked with 1).
1. Transmission housing
2. Adjustment shim "S3"
3. Outer race for double tapered roller bearing
^ Pulling out
^ Pressing in
4. Pinion shaft
^ Matched to ring gear, always replace together as a set
5. Inner race for double tapered roller bearing
^ Damaged when removed
^ Replace
^ Pressing off
^ Pressing on
6. Circlip
^ Re-determining thickness when replacing double tapered roller bearing
7. Needle bearing
^ For pinion shaft in hollow shaft
^ Lubricate with grease MoS2
8. Hollow shaft 1)
9. Needle bearing for 1st gear
10. Needle bearing for 1st gear
11. 1st gear sliding gear
12. Inner race for 1st gear
^ Installation position
^ Checking for wear
^ Replace if scored or show signs of wear
13. Intermediate ring for 1st gear
^ Installation position
^ Checking for wear
14. Synchronizer ring for 1st gear
^ Installation position
^ Checking for wear
^ Replace if scored or show signs of wear
15. Sliding sleeve for 1st and 2nd gear
^ Mark installation position +Assembling sliding sleeve/synchronizer hub
16. Thrust piece
^ Installing thrust pieces (3x)
17. Synchronizer hub for 1st and 2nd gears
^ Pressing off
^ Pressing on
^ Assembling sliding sleeve/synchronizer hub
18. Circlip
^ Identification
^ Installation position, - item 1 -
^ Re-determining thickness when replacing synchronizer body or hollow shaft
19. Needle bearing
^ For 2nd gear
20. Synchronizer ring for 2nd gear
^ Installation position
^ Checking for wear
^ Replace if scored or show signs of wear
21. Intermediate ring for 2nd gear
^ Installation position
^ Checking for wear
22. Inner race for 2nd gear
^ Installation position
^ Checking for wear
^ Replace if scored or show signs of wear
23. 2nd gear sliding gear
24. Circlip
^ Identification
^ Installation position, - item 2 -
25. 3rd-gear gear wheel
^ Pressing off
^ Groove points to 4th gear
^ Pressing on
26. Circlip
^ Identification
^ Installation position, - item 3 -
^ If 3rd-gear gear wheel or hollow shaft is replaced, re-determine thickness of circlip
27. 4th-gear gear wheel
^ Pressing off
^ Collar faces 3rd gear
^ Pressing on
28. Circlip
^ Identification
^ Installation position, - item 4 -
^ If 4th-gear gear wheel or hollow shaft is replaced, re-determine thickness of circlip
29. Needle bearing
30. 5th gear sliding gear
^ Modification characteristic
31. Spring
^ Modification characteristic
^ Inserting in 5th gear sliding gear
^ Allocation to sliding gear Electronic Parts Catalog (ETKA)
32. Synchronizer ring for 5th gear
^ Modification characteristic
^ Checking for wear
33. Circlip
^ Identification
^ Installation position, - item 5 -
34. Synchronizer hub 5th gear and reverse gear
^ Modification characteristic
^ Pressing off
^ Pressing on
35. Circlip
^ Identification
^ Installation position, - item 6 -
^ Re-determining thickness when replacing synchronizer body or hollow shaft
36. Needle bearing
^ For reverse gear
37. Sliding sleeve for 5th and reverse gear
^ Modification characteristic
^ Installation position: Groove points to 5th gear sliding gear
38. Synchronizer ring for reverse gear
^ Modification characteristic
^ Checking for wear
39. Spring
^ Modification characteristic
^ Inserting in reverse gear sliding gear
40. Sliding gear for reverse gear
^ Modification characteristic
41. Circlip
^ Identification
^ Installation position, - item 7 -
42. Tapered roller bearing inner race
^ Pressing off
^ Pressing on
43. Socket
^ Secures outer race for small tapered roller bearing
^ Pulling out
^ No longer needs to be installed after replacing small tapered roller bearing.
44. Tapered roller bearing outer race
^ Pressing out
^ Pressing in
45. Adjustment shim "S4"
46. Ring
^ For mounting rubber washer
^ Allocate according to Electronic Parts Catalog (ETKA)
47. Rubber washer
^ Compensated length variations
48. Transmission cover
^ Coat sealing surfaces thinly with sealant AMV 188 00102
Synchronization of 5th gear and reverse gear modified as of transmission manufacture date 23 06 3
Note:
^ Parts of old construction type up to transmission manufacture date 22 06 3 and parts of new construction type as of transmission manufacture date 23 06 3 cannot be installed interchanged with each other.
The following components have been modified:
1. 5th gear sliding gear
2. Synchronizer spring
3. Synchronizer ring for 5th gear
4. Synchronizer hub for 5th and reverse gear
5. Sliding sleeve for 5th and reverse gear
6. Synchronizer ring for reverse gear
7. Synchronizer spring
8. Sliding gear for reverse gear
Scope of modification:
^ Reduced gear splining - arrows A -
^ Synchronizer rings with enlarged friction cone - arrows B -
Pulling out outer race for double tapered roller bearing
^ Remove differential.
^ Place pressure piece bushing puller 3128 under outer race.
^ Assemble threaded piece of bushing puller 3128 with pressure plate VW 401 onto transmission housing.
When the bolt is tightened, the outer race will be pulled out of housing.
Pressing in outer race for double tapered roller bearing
Smaller diameter of thrust pad 3062 points toward outer race.
Pressing off inner race for double tapered roller bearing
^ Remove circlip before pressing off.
^ Outer race - A - must be installed to press off inner race.
Pressing on inner race for double tapered roller bearing
Determining circlip
^ Determine thickest circlip which can still just be installed and insert.
Note:
^ Circlips for synchronizer hubs and gear wheels of individual gears should be determined as for double tapered roller beating as shown.
Pulling out locking bushing for outer race for tapered roller bearing
A - Internal puller 12 to 14.5 mm, e.g. Kukko 21/1
Pressing out outer race for tapered roller bearing
^ Outer race is pressed out together with ring of adjustment shim "S4" and rubber washer for longitudinal compensation.
Pressing in tapered roller bearing outer race
Pressing off inner race for tapered roller bearing
^ Press off inner race together with reverse gear sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing on tapered roller bearing inner race
^ Before pressing on inner race, install circlip.
Pressing off synchronizer hub for 5th gear and reverse gear
^ Remove circlip before pressing off.
^ Press off synchronizer hub with 5th gear sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off 4th-gear gear wheel
^ Remove circlip before pressing off.
Pressing off 3rd-gear gear wheel
^ Remove circlip before pressing off.
Note:
^ When pressing off, make sure that only the gear wheel teeth - arrows - and not sliding gear splines make contact on separating device - A -. Otherwise gear splining will be damaged.
^ Press off 3rd-gear gear wheel with 2nd gear sliding 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 sliding gear.
Installation position of circlips
^ Circlips for synchronizer hubs, needle bearings and gear wheels of individual gears should be determined as shown
Circlip - 1 - secures synchronizer hub 1st and 2nd gear.
Characteristic: Blue color
Circlip - 2 - secures needle bearing/2nd gear sliding gear
Characteristic: Blue color
Circlip - 3 - secures the 3rdgear gear wheel
Circlip - 4 - secures 4th-gear gear wheel
Circlip - 5 - secures needle bearing/5th gear sliding gear
Characteristic: Brown color
Circlip - 6 - secures synchronizer hub 5th and reverse gear.
Characteristic: Blue color
Circlip - 7 - secures needle bearing for reverse gear sliding gear.
Determine circlips according to table.
Installation position of synchronizer rings for 1st and 2nd gear
Note:
^ If the components are not going to be replaced, be sure that they are installed on the same gear.
^ Place inner race - 2 - on sliding gear - 1 -.
^ Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
^ Synchronizer ring - 4 -installed. Guide tabs - C - through recess - arrow -.
Checking inner race of 1st gear for wear
^ Check outer friction surface - arrow - for scoring or signs of wear, replace if necessary.
^ Press inner race onto cone of sliding gear and measure gap dimension - a - using a feeler gauge.
Checking intermediate ring of 1st and 2nd gear for wear
^ Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
^ Press inner race, intermediate ring and synchronizer ring onto cone of sliding gear and measure gap dimension - a - using a feeler gauge.
Pressing on synchronizer hub for 1st and 2nd gears
^ Installation position:
Higher inner collar faces 2nd gear
Assembly of sliding sleeve/synchronizers for 1st and 2nd gear
^ Insert pressure pieces - arrows A - into installed synchronizer hubs - 1 -.
^ Place sliding sleeve - 2 - over synchronizer hub so that wide tooth spacing of sliding sleeve and synchronizer hub - arrow B - align with each other.
Pressing on 3rd-gear wheel
Installation position: The groove on gear wheel faces 4th gear.
Pressing on 4th gear wheel
Installation position: High inner collar, groove on gear wheel faces 3rd gear.
Inserting spring into sliding gear
The bent end of spring - arrow - must be hooked into hole of sliding gear.
Checking synchronizer ring for wear
^ Press synchronizer ring into sliding sleeve and measure gap dimension - a - at positions - A -, - B - and - C - using a feeler gauge.
^ Add measured values and divide total by three to calculate average.
Determined value must not exceed 0.45 mm.
Pressing on synchronizer hub for 5th gear and reverse gear
Installation position: High inner collar faces 5th gear.
Installation position of sliding sleeve for 5th and reverse gear
^ Installation position:
Groove - arrow - points to 5th gear sliding gear