Output Shaft

Output Shaft

Special tools, testers and auxiliary items required

• Punch (VW 407)

• Thrust Disc (VW 412)

• Thrust Pad (VW 512)

• Taper Roller Bearing Puller (V.A.G 1582)

• Attachment to VAG 1582 (V.A.G 1582/4)

• Attachment to VAG 1582 (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 60 mm Dia. (VW 415 A)

• Thrust Pad (VW 447 H)

• Thrust Tube (VW 454)

• Thrust Tube (VW 455)

• Mounting Universal Joint (41-501)

• Kukko Extractor 37-46 mm (21/6)

• Kukko Support (22/2)

• Kukko Separating Tool 22-115 mm (17/2)

• Disassemble the output shaft as follows: place the separating device under the 2nd gear - item 21 - and remove it as described. Refer to => [ Removing the Synchronizer and 3rd/4th
Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing
Sleeve and Output Shaft ]. Remove the locking ring - item 17 -. Remove the locking collar and the 1st/2nd gear synchronizer hub as described in => [ Removing the Locking Collar with the
Synchronizer Hub and Bearing Mount ].

• Refer to the Parts Catalog and to the technical data, refer to => [ Code Letters, Transmission Allocation and Capacities ] Code Letters, Transmission Allocation and Capacities, when installing new gears or a new input shaft.

• Replace both tapered roller bearings together.

1 Nut

• 25 Nm + 90 degrees additional turn.

• Quantity: 4, for the bearing mount.

• Always replace

2 Clutch Housing

3 Adjusting Shim

• For the output shaft.

• Adjustment overview, refer to => [ Adjustment Overview ] Adjustment Overview.

4 Small Outer Race/Tapered Roller Bearing

• Removing, refer to => [ Removing the Small Outer Race/Tapered
Roller Bearing ].

• Installing, refer to => [ Installing the Small Outer Race/Tapered
Roller Bearing ].

5 Bearing Inner Race/Small Tapered Roller Bearing

• Removing, refer to => [ Removing the Inner Race/Small Tapered
Roller Bearing ].

• Installing, refer to => [ Installing the Inner Race/Small Tapered
Roller Bearing ].

6 Output Shaft

• Adjusting, refer to => [ Output Shaft, Adjusting ] Output Shaft, Adjusting.

7 Bearing Inner Race/Large Tapered Roller Bearing

• Removing, refer to => [ Removing the Inner Race/Large Tapered
Roller Bearing ].

• Installing, refer to => [ Installing the Inner Race/Large Tapered
Roller Bearing ].

8 Seal

• Place the four seals on the bearing mount bolts.

9 Bearing Mount

• With the large outer race/tapered roller bearing and bolts.

• Replace the outer race only together with the large tapered roller bearing and bearing mount.

10 Thrust Washer

• The collar on the thrust washer faces the tapered roller bearing.

11 1st Gear

12 Needle Bearing

• For the 1st gear.

13 Synchronizer Ring

• (Inner race for 1st gear)

• Installed position, refer to => [ Installed Position of the Inner Race,
the Outer Race and the 1st Gear Synchronizer Ring ].

• Checking for wear, refer to => [ Checking Inner Race for 1st Gear and
2nd Gear for Wear ].

• Check for scoring.

14 1st Gear Outer Race

• Installed position, refer to => [ Installed Position of the Inner Race,
the Outer Race and the 1st Gear Synchronizer Ring ].

• Checking for wear, refer to => [ Checking 1st Gear and 2nd Gear Synchronizing
Ring for Wear ].

• Replace if there are grooves or scoring.

15 1st Gear Synchronizer Ring

• Installed position, refer to => [ Installed Position of the Inner Race,
the Outer Race and the 1st Gear Synchronizer Ring ].

• Checking for wear, refer to => [ Checking 1st Gear and 2nd Gear Synchronizing
Ring for Wear ].

16 Locking Collar with Synchronizer Hub for 1st and 2nd Gears

• After removing the locking ring - item 17 -, remove with the bearing mount. Refer to => [ Removing the Locking Collar with the
Synchronizer Hub and Bearing Mount ].

• Disassembling, refer to => [ Disassembling and Assembling Locking
Collar and Synchronizer Hub for 1st and 2nd Gears ].

• Assembling the operating sleeve/synchronizer hub, refer to => [ Disassembling and Assembling Locking
Collar and Synchronizer Hub for 1st and 2nd Gears ] , => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow
on the Inside ] and => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are not
Hollow ].

• Installed position, refer to => [ Installed Position: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ].

• Installing, refer to => [ Installing the Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ].

17 Locking Ring

18 2nd Gear Synchronizer Ring

• Checking for wear, refer to => [ Checking 1st Gear and 2nd Gear Synchronizing
Ring for Wear ].

• Insert it so that the holes engage into engagement pieces of locking collar - item 16 -.

19 2nd Gear Outer Race

• Insert into synchronizer ring - item 18 -.

• Installed position, refer to => [ Installed Position of 2nd Gear Outer
Race ].

• Replace if there are grooves or scoring.

20 Synchronizer Ring

• (Inner race for 2nd gear)

• Checking for wear, refer to => [ Checking 1st Gear and 2nd Gear Synchronizing
Ring for Wear ].

• Check for scoring.

• Installed position, refer to => [ Installed Position: Synchronizer Ring (2nd Gear Inner Race) ].

21 2nd Gear

• Installed position, refer to => [ Installed Position: 2nd Gear ].

22 Needle Bearing

• For 2nd gear.

23 Thrust Washer

24 Sleeve for the 3rd Gear Needle Bearing

• Removing with the 2nd gear, refer to => [ Removing the Synchronizer and 3rd/4th
Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing
Sleeve and Output Shaft ].

• Installing, refer to => [ Installing the Sleeve for the 3rd Gear
Needle Bearing ].

25 Needle Bearing

• For 3rd gear.

26 3rd Gear

27 3rd Gear Synchronizer Ring

• Checking for wear, refer to => [ Checking 3rd/4th Gear Synchronizing
Ring for Wear ].

28 Locking Collar with Synchronizer Hub for 3rd and 4th Gears

• Remove with 2nd gear - item 21 - and 3rd gear - item 26 -. Refer to => [ Removing the Synchronizer and 3rd/4th
Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing
Sleeve and Output Shaft ].

• Disassembling, refer to => [ Disassembling and Assembling: Locking
Collar and Synchronizer Hub for 3rd/4th Gears ].

• Assembling operating sleeve/synchronizer hub, refer to => [ Disassembling and Assembling: Locking
Collar and Synchronizer Hub for 3rd/4th Gears ] , => [ Assembly: Locking Collar/Synchronizer
Hub for 3rd and 4th Gears together with Locking Pieces that are Hollow
on the Inside ] and => [ Assembly: Locking Collar/Synchronizer
Hub for 3rd and 4th Gears together with Locking Pieces that are not
Hollow ].

• Installed position: locking collar/synchronizer hub, refer to => [ Installed Position: Locking Collar/Synchronizer
Hub for 3rd and 4th Gears ].

• Installing, refer to => [ Installing the Synchronizer Hub with
Locking Collar for 3rd and 4th Gears ].

29 Sleeve

• For the needle bearing.

• Removing with the locking collar and the 3rd/4th gear synchronizer hub - item 28 -, refer to => [ Removing the Synchronizer and 3rd/4th
Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing
Sleeve and Output Shaft ].

• Installing, refer to => [ Installing the Sleeve for the 4th Gear
Needle Bearing ].

30 Needle Bearing

• For 4th gear

31 4th Gear Synchronizer Ring

• Checking for wear, refer to => [ Checking 3rd/4th Gear Synchronizing
Ring for Wear ].

32 4th Gear

33 Thrust Washer

34 Needle Bearing

• For the output shaft.

• Removing and installing, refer to => [ Needle Bearing, Removing ] Transmission and Clutch Housings.

35 Transmission Housing

36 Sleeve

• For the needle bearing/output shaft.

• Removing, refer to => [ Removing the Synchronizer and 3rd/4th
Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing
Sleeve and Output Shaft ].

• Installing, refer to => [ Installing the Sleeve for the Needle
Bearing/Output Shaft ].

37 5th Gear

• Removing and installing, refer to => [ Transmission ] Transmission.

38 Plate Spring

• Installed position, refer to => [ Installed Position of the Concave Washers
for the 5th Gear Synchronizing Hub and Gear Bolts ] Transmission.

39 Bolt

• See - item 4 - in => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.

• Always replace

• Removing and installing, refer to => [ Transmission ] Transmission.

Removing the Small Outer Race/Tapered Roller Bearing

A Extractor 37-46 mm, for example, (21/6)
B Support, for example, (22/2)

Installing the Small Outer Race/Tapered Roller Bearing

Removing the Inner Race/Small Tapered Roller Bearing

A Protective jaws/vise

- Mount the grip and apply tension behind the rolling the bearing. Then rotate the bearing and apply tension to the grip.

Installing the Inner Race/Small Tapered Roller Bearing

Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft

A Separating tool 22-115 mm, for example, (17/2)
B M10 x 20, 17 mm bolt

• Support the separating tool so that the 1st/2nd gear locking collar does not come off as well.

Removing the Locking Collar with the Synchronizer Hub and Bearing Mount

- Remove the locking ring - arrow - first.

Removing the Inner Race/Large Tapered Roller Bearing

A - Jaw protectors

- Before installing puller, insert a M10 x 20 bolt into the hole in the output shaft.

Installing the Inner Race/Large Tapered Roller Bearing

- A - thrust washer

- Install the thrust washer before installing the inner race. The shoulder faces the inner race.

Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring

- Place the inner race - A - on the drive gear for 1st gear.

The angled tabs - arrow 1 - face the outer race - B -.

- Install the outer race - B -.

The tabs - arrow 2 - must lock into the retainers - arrow 3 - in the gear wheel.

- Install the synchronizer ring - C -.

The retainers - arrow 4 - lock in the tabs - arrow 1 - on the inner race - A -.

• If the parts are not to be replaced, make sure they are reallocated to their original gear.

Checking Inner Race for 1st Gear and 2nd Gear for Wear

- Press the inner race onto taper on the gear wheel and measure the gap dimension - a - with a feeler gauge.

Checking 1st Gear and 2nd Gear Synchronizing Ring for Wear

- Install the synchronizer ring, outer race and inner race onto taper of selector gear and then measure the gap dimension - a - with a feeler gauge.

Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears

1 Spring

For the correct spring, refer to the Parts Catalog.

Assembly in conjunction with hollow locking pieces, refer to => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow
on the Inside ].

Assembly in conjunction with locking pieces that are not hollow, refer to => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are not
Hollow ].

2 Locking collar
3 Synchronizer hub
4 Locking piece

For the correct locking pieces, refer to the Parts Catalog.

The collar has the same width on both side of the synchronizer hub.

The shoulder has a chamfer on one side - arrow B -.

The bevel on the synchronizer hub collar and the splines on the outside of the locking collar - arrow A - face in the same direction after being assembled.

The notches on the synchronizer hub and locking collar for the locking pieces - arrow C - must line up.

Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow on the Inside

• The locking collar is pushed over the synchronizer hub.

- Install the locking pieces and springs offset by 120 degrees . The angled end of the spring must engage into the hollow locking piece.

Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are not Hollow

• The locking collar is pushed over the synchronizer hub.

- Install the locking pieces and springs offset by 120 degrees . The angled end of the spring must be positioned in front of the locking pieces - arrows -.

Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears

The teeth of the locking collar - arrow - point toward the splines of the 3rd/4th gear synchronizer hub - A -.

Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears

Turn the synchronizer ring so that the grooves line up with the locking pieces.

Installed Position of 2nd Gear Outer Race

The tabs - arrows - face 1st gear - A -.

Installed Position: Synchronizer Ring - A - (2nd Gear Inner Race)

The tabs - arrow 1 - engage into the holes - arrow 2 - inside the synchronizer ring - B -.

Installed Position: 2nd Gear

The higher collar - A - faces toward 1st gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race, refer to => [ Installed Position of 2nd Gear Outer
Race ].

Installing the Sleeve for the 3rd Gear Needle Bearing

Checking 3rd/4th Gear Synchronizing Ring for Wear

- Press the synchronizer ring onto the taper of the gear wheel and measure the gap dimension - a - with a feeler gauge.

Disassembling and Assembling: Locking Collar and Synchronizer Hub for 3rd/4th Gears

1 Spring

For the correct spring, refer to the Parts Catalog.

Assembly in conjunction with hollow locking pieces, refer to => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow
on the Inside ].

Assembly in conjunction with locking pieces that are not hollow, refer to => [ Assembly: Locking Collar/Synchronizer
Hub for 1st and 2nd Gears together with Locking Pieces that are not
Hollow ].

2 Locking piece

For the correct locking pieces, refer to the Parts Catalog.

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.

Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are Hollow on the Inside

The locking collar is pushed over the synchronizer hub.

- Install the locking pieces and springs offset by 120 degrees . The angled end of the spring must engage into the hollow locking piece.

Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are not Hollow

The bevel - arrow - faces 4th gear.

Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears

Installing the Sleeve for the 4th Gear Needle Bearing

Installing the Sleeve for the Needle Bearing/Output Shaft