Output Shaft, 5th, 6th and Reverse Gears
Output Shaft, 5th, 6th and Reverse Gears
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 60 mm Dia. (VW 415 A)
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Support Channels (VW 457)
• Holding Fixture (VW 801)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Tube (VW 455)
• Thrust Pad (VW 510)
• Tube 42 mm Dia. (VW 516)
• Sleeve (VW 519)
• Thrust Pad (30-11)
• Thrust Piece (40-105)
• Sleeve (40-20)
• Thrust Plate (2050)
• Tube (3296)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/4)
• Grip (V.A.G 1582/7)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
• Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
• Replace both tapered roller bearings together.
1 Clutch Housing
2 Washer
• Always 0.65 mm thick.
3 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing in the Clutch Housing ].
4 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered Roller
Bearing ].
5 Output Shaft
• For the 5th, 6th and reverse gears.
• Adjusting, refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
6 Reverse Gear Synchronizer Hub
• Removing, refer to => [ Removing the Reverse Gear Synchronizer
Hub ].
• Installed position, refer to => [ Installed Position: Reverse Gear Synchronizer
Hub ].
• Installing, refer to => [ Installing the Reverse Gear Synchronizer
Hub ].
7 Locking Ring
8 Reverse Gear Locking Collar
• With the synchronizer ring.
9 Needle Bearing
• For the reverse gear.
10 Reverse Gear
11 Needle Sleeve
• Remove with the reverse gear, refer to => [ Removing the Sleeve together with the Reverse Gear ].
• Installed position: the wider collar on the sleeve points toward the reverse gear selector gear.
• Installing, refer to => [ Installing the Sleeve ].
12 Locking Ring
13 Needle Bearing
• For the 6th gear.
14 6th Gear
15 Synchronizer Ring for 6th Gear
• Checking for wear, refer to => [ Checking 5th and 6th Gear Synchronizing
Ring for Wear ].
16 Locking Collar with Synchronizer Hub for 5th and 6th Gears
• After removing the locking ring => [ (Item 17) Locking Ring ] , remove the 6th gear, refer to => [ Removing the 5th and 6th Gear Synchronizer
Hub/Locking Collar and the 6th Gear ].
• Disassembling, refer to => [ Disassembling and Assembling Locking
Collar and Synchronizer Hub for 5th and 6th Gears ].
• Assembling the locking collar/synchronizer hub, refer to => [ Disassembling and Assembling Locking
Collar and Synchronizer Hub for 5th and 6th Gears ] and to => [ Assembling Locking Collar/Synchronizer
Hub for 5th and 6th Gears ].
• Installing, refer to => [ Installing the Locking Collar/Synchronizer
Hub for 5th and 6th Gears ].
17 Locking Ring
18 Needle Bearing
• For the 5th gear.
19 5th Gear Synchronizer Ring
• Checking for wear, refer to => [ Checking 5th and 6th Gear Synchronizing
Ring for Wear ].
20 5th Gear
21 Inner Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Inner Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Inner Race/Tapered Roller
Bearing ].
22 Locking Ring
• Select the correct one when replacing the tapered roller bearing => [ (Item 21) Inner Race/Tapered Roller Bearing ] and the output shaft => [ (Item 5) Output Shaft ]. Refer to => [ Selecting the Locking Ring ].
23 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing from the Transmission Housing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing into the Transmission Housing ].
24 Adjusting Shim
• To select the correct thickness, refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
25 Transmission Housing
26 Spring
• Installed position, refer to => [ Assembling Locking Collar/Synchronizer
Hub for 5th and 6th Gears ].
27 Locking Sleeve
28 Synchronizer Hub
29 Locking Pieces
• Quantity: 3
• Installed position, Refer to => [ Disassembling and Assembling Locking
Collar and Synchronizer Hub for 5th and 6th Gears ].
Removing the Outer Race/Tapered Roller Bearing
A Counter-support, for example, kukko support (22/2)
B Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm (21/7)
• Check the washer for damage after removing it and replace if necessary.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Place the washer under the outer race.
- Support the clutch housing using the sleeve (40-20) directly under the bearing mount.
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
A Counter-support, for example, kukko support (22/2)
B Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm (21/7)
Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing
- Support the transmission housing under the bearing mount using the thrust plate (2050).
Disassembling the Output Shaft
Removing the Inner Race/Tapered Roller Bearing
Before installing the tapered roller bearing puller:
- Remove the inner race/tapered roller bearing locking ring on the side facing the transmission housing.
- Mount the thrust pad 16.5/28 mm dia. (VW 431) and thrust piece (40-105) on the output shaft.
Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar and the 6th Gear
- Remove the locking ring beforehand.
Removing the Sleeve - A - together with the Reverse Gear
- Remove the locking ring beforehand.
Removing the Reverse Gear Synchronizer Hub
- Remove the locking ring beforehand.
A Separating tool 22 to 115 mm, for example, kukko separating tool 22-115 mm (17/2)
Removing the Inner Race/Tapered Roller Bearing
- Mount the thrust pad (30-11) on the output shaft before removing the puller.
Assembling the Output Shaft
Installed Position: Reverse Gear Synchronizer Hub
The stop - arrow A - on the reverse gear locking collar faces the splines on the output shaft - arrow B -.
Installing the Reverse Gear Synchronizer Hub
- Install the locking ring.
- Mount the reverse gear locking collar on the reverse gear synchronizer hub.
- Install the reverse gear and the needle bearing.
Installing the Sleeve - A -
Installed position: wide collar points toward reverse gear selector gear.
- Install the locking ring.
Checking 5th and 6th Gear Synchronizing Ring for Wear
- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - with a feeler gauge.
Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.
Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears
The locking collar is pushed over the synchronizer hub.
- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.
- Install the 6th gear with needle bearing.
- Install the 6th gear synchronizer ring.
Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears
On some locking collars, there is a chamfer on the outer diameter.
Installed position: the chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the locking ring.
- Install the 5th gear synchronizer ring.
- Install 5th gear selector gear with needle bearing.
Installing the Inner Race/Tapered Roller Bearing
- Choose the correct locking ring, refer to => [ Selecting the Locking Ring ] and install.
Selecting the Locking Ring
- Choose and install the thickest locking ring that will fit.
- Select the locking ring according to the table. For the correct part number, refer to the Parts Catalog.
Available Locking Rings
Installing the Inner Race/Tapered Roller Bearing
