Output Shaft
Output Shaft
Special tools, testers and auxiliary items required
• Punch (VW 407)
• Punch (VW 412)
• Thrust pad (VW 512)
• Taper roller bearing puller (V.A.G 1582)
• Attachment (V.A.G 1582/4)
• Attachment (V.A.G 1582/5)
• Thrust plate (VW 402)
• Driving sleeve (32 - 111)
• Punch (VW 408 A)
• Punch (VW 409)
• Support channels (VW 457)
• Sleeve (VW 519)
• Thrust ring (VW 429)
• Tube (VW 415 A)
• Thrust pad (VW 447 H)
• Thrust tube (VW 454)
• Pressing sleeve (VW 455)
• Drive bushing (41 - 501)
• Seal driver-frt wheel bearing (30 - 100)
• Tube (2040)
• Internal extractor (Kukko 21/6)
• Separating tool (Kukko 17/2 )
• Counter-support (Kukko 22/2 )
Pulling off small outer race/tapered roller bearing
A Internal puller 37 to 46 mm, e.g. (Kukko 21/6)
B Support, e.g. ( Kukko 22/2)
Pressing in small outer race/tapered roller bearing
Pulling off small inner race/tapered roller bearing
A Jaw protectors/vise
- Install gripping piece and tension thoroughly behind bearing rollers, then turn bearing and retention gripping piece.
Pressing on small tapered roller bearing inner race
Pressing off 3rd and 4th gear synchronizer hub/locking collar, 2nd, 3rd and 4th gear shift gears with needle bearing sleeve
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
B Hex bolt SW 17 M10 x 20
• Support separating device so that the 1st and 2nd gear locking collar is not pulled off at the same time.
Pressing off locking collar with synchronizer hub and bearing mount
- First remove circlip - arrow -.
Pulling off large inner race/tapered roller bearing
A Protective pads/vise
- Before installing puller, insert hex bolt M10 x 20 into bore of output shaft.
Pressing on inner race of large taper roller bearing
A Thrust washer
- Insert thrust washer before pressing on inner race. The shoulder faces toward inner race.
Installed position of inner race, outer race and synchronizer ring for 1st gear
- Place inner race - A - on shift gear for 1st gear.
The bent tabs - arrow 1 - face toward outer race - B -.
- Install outer race - B -.
The tabs - arrow 2 - engage in notches - arrow 3 - of shift gear.
- Install synchronizer ring - C -.
The notches - arrow 4 - engage in tabs - arrow 1 - of inner race - A -.
• If the components are not to be replaced, make sure they are installed to their original gear.
Checking inner race of 1st and 2nd gear for wear
- Press inner race onto taper of shift gear and measure gap dimension - a - using a feeler gauge.
Checking synchronizer ring of 1st gear and 2nd gear for wear
- Press synchronizer ring, outer race and inner race onto taper of shift gear and measure gap dimension - a - using a feeler gauge.
Disassembling and assembling locking collar and synchronizer hub for 1st and 2nd gear
1 Spring
Assembly in conjunction with hollow locking pieces => [ Assembling locking collar/synchronizer hub
of 1st and 2nd gear in conjunction with hollow locking pieces ]
Assembly in conjunction with locking pieces that are not hollow => [ Assembling sliding sleeve/synchronizer 1st
and 2nd gear in conjunction with engaging pieces that are not hollow ]
2 Locking collar
3 Synchronizer hub
4 Locking piece
The shoulder is the same width on both sides of synchronizer hub.
The shoulder has a chamfer on one side - arrow B -.
After assembly, the chamfer on the shoulder of synchronizer hub and outer splines of locking collar - arrow A - face same direction.
Recesses for locking pieces on synchronizer hub and locking collar - arrow C - must aligned.
Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces
• Sliding sleeve is slid over synchronizer hub.
- Insert engaging pieces and install springs at 120 degrees offset. Spring must engage with angled end into hollow engaging piece.
Assembling sliding sleeve/synchronizer 1st and 2nd gear in conjunction with engaging pieces that are not hollow
• The locking collar is pushed over synchronizer hub.
- Insert locking pieces and install the springs 120 degrees offset. The angled end of the spring must be positioned in front of the locking pieces- arrows -.
Installation position of locking collar/synchronizer hub for 1st and 2nd gear
The teeth of locking collar - arrow - point toward splines of 3rd/4th gear synchronizer hub - A -.
Pressing on locking collar/synchronizer hub for 1st and 2nd gear
Turn synchronizer ring so that the grooves align with locking pieces.
Installation position of 2nd gear outer race
Tabs - arrows - face toward 1st gear - A -.
Installation position of synchronizer ring (2nd gear inner race) - A -
Tabs - arrow 1 - engage into cut-outs - arrow 2 - of synchronizer ring - B -.
Installation position of 2nd gear shift gear
Higher collar - A - faces toward 1st gear - B -. Recesses in collar - arrows - engage into outer race tabs => [ Installation position of 2nd gear outer race ]
Pressing on sleeve for 3rd gear needle bearing
Checking synchronizer ring of 3rd and 4th gears for wear
- Press synchronizer ring onto taper of shift gear and measure gap dimension - a - using a feeler gauge.
Disassembling and assembling locking collar and synchronizer hub for 3rd and 4th gear
1 Spring
Assembly in conjunction with hollow locking pieces => [ Assembling locking collar/synchronizer hub of 1st and 2nd gear in conjunction with hollow locking pieces ]
Assembly in conjunction with locking pieces that are not hollow => [ Assembling sliding sleeve/synchronizer 1st
and 2nd gear in conjunction with engaging pieces that are not hollow ]
2 Locking piece
3 Locking collar
4 Synchronizer hub
- Slide locking collar over synchronizer hub.
The recesses for locking pieces in synchronizer hub and locking collar must align.
Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with hollow locking pieces
• Sliding sleeve is slid over synchronizer hub.
- Insert locking pieces and install the springs 120 degrees offset. Spring must engage with angled end into hollow engaging piece.
Assembling locking collar/synchronizer hub of 3rd and 4th gear in conjunction with locking pieces that are not hollow
• The locking collar is pushed over synchronizer hub.
- Insert locking pieces and install the springs 120 degrees offset. The angled end of spring must be positioned in front of locking pieces - arrows -.
Installation position of locking collar/synchronizer hub for 3rd and 4th gear
Chamfer - arrow - faces 4th gear.
Pressing on synchronizer hub with locking collar for 3rd and 4th gears
Pressing on sleeve for 4th gear needle bearing
- Assemble synchronizer ring 4th gear, needle bearing 4th gear, gear-wheel 4th gear and thrust washer.
Pressing on sleeve for output shaft needle bearing
