Output Shaft, 1st through 4th Gears
Output Shaft, 1st through 4th 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 (VW 415 A)
• Holding plate (VW 309)
• Holding fixture (VW 313)
• Transmission support (VW 353)
• Thrust pad 16.5/28 mm dia. (VW 431)
• Thrust pad con. 8/65 (VW433)
• Thrust tube (VW454)
• Thrust plate (VW 512)
• Tube (VW 516)
• Tube (VW 519)
• Slide hammer-complete set (VW 771)
• Holding fixture (VW 801)
• Thrust piece (40 - 105)
• Seal driver-frt wheel bearing (40 - 20)
• Seal driver-frt wheel bearing (40 - 21)
• Thrust plate (2050)
• Extension (3161)
• Taper roller bearing puller (V.A.G 1582)
• Attachment (V.A.G 1582/7)
• Internal extractor (Kukko 21/7)
• Internal extractor (Kukko 21/8)
• Puller (Kukko 18/2)
• Separating tool (Kukko 17/2)
• Support (Kukko 22/2)
• If output shaft or tapered roller bearings are replaced, an adjustment on output shaft must be performed --> [ Output Shaft, 1st through 4th Gears, Adjusting ] Output Shaft, 1st through 4th Gears, Adjusting.
• Replace both tapered roller bearings together as a set.
1 Clutch housing
2 Oil deflector ring
3 Dished washer
• Pulling out --> [ Pull Dished Washer Out
of Output Shaft ]
• Pressing in --> [ Pressing Dished Washer in Output Shaft to Stop ]
4 Tapered roller bearing outer race
• Pulling out --> [ Pulling Out Tapered Roller Bearing Outer Race ]
• Pressing in --> [ Pressing Outer Race/Tapered Roller Bearing into Clutch Housing ]
5 Inner race/tapered roller bearing
• Pressing off --> [ Pressing Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
6 Output shaft
• For 1st to 4th gear
• Adjusting --> [ Output Shaft, 1st through 4th Gears, Adjusting ] Output Shaft, 1st through 4th Gears, Adjusting.
7 Needle bearing
• For 2nd gear
8 Selector gear for 2nd gear
9 Synchronizer ring
• (Inner race for 2nd gear)
• Checking for wear --> [ Checking Inner Race for 1st Gear, 2nd Gear and 3rd Gear for Wear ]
• Checking tabs for scoring
• Installed location --> [ Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear ]
10 Outer race for 2nd gear
• Install on synchronizer ring --> [ 9 Synchronizer ring ]
• Replace if grooved or scored
• Installed location --> [ Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear ]
11 Synchronizer ring for 2nd gear
• Checking for wear --> [ Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear ]
• Installed location --> [ Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear ]
12 Locking sleeve with synchronizer hub for 1st and 2nd gears
• After removing circlip --> [ (item 13) Circlip ] , press off gear wheel for 2nd gear --> [ Pressing Off Locking Collar and Synchronizer Hub for 1st and 2nd Gears ]
• Disassembling --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ]
• Assembling locking collar/synchronizer hub --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ] and --> [ Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ]
• Installed location --> [ Installation Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear ]
• Pressing on --> [ Pressing On Locking Collar/Synchronizer Hub for 1st and 2nd Gear ]
13 Circlip
14 Synchronizer ring for 1st gear
• Checking for wear --> [ Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear ]
• Insert so that cut outs engage in engagement pieces of locking collar --> [ 12 Locking sleeve with synchronizer hub for 1st and 2nd gears ]
15 Outer race for 1st gear
• Insert into synchronizer ring --> [ 14 Synchronizer ring for 1st gear ] , installation position --> [ Installed Location of Outer Race for 1st and 3rd Gear ]
• Replace if grooved or scored
16 Synchronizer ring
• (Inner race for 1st gear)
• Checking for wear --> [ Checking Inner Race for 1st Gear, 2nd Gear and 3rd Gear for Wear ]
• Check tabs for scoring
• Installed location --> [ Installation Location of Synchronizer Ring (Inner Race for 1st and 3rd Gear) ]
17 Needle bearing
• For 1st gear
18 Selector gear for 1st gear
• Installed location --> [ Installation Position of Selector Gear for 1st and 3rd Gear ]
19 Thrust washers
• For 1st and 4th gear
• Quantity: 2
• Insert tab of thrust washer into output shaft hole
20 Washer
• Holds thrust washers --> [ (item 19) Thrust washers ] in position on output shaft
21 Needle bearing
• For 4th gear
22 Selector gear for 4th gear
23 Synchronizer ring for 4th gear
• Checking for wear --> [ Checking Synchronizer Ring for 4th Gear for Wear ]
24 Locking collar with synchronizer hub for 3rd and 4th gear
• After removing circlip --> [ 25 Circlip ] , pull off with selector gear for 4th gear--> [ Pulling Off Synchronizer Hub/Locking Collar for 3rd and 4th Gear with Selector Gear for 4th Gear ]
• Disassembling --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ]
• Assembling locking collar/synchronizer hub --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ] and --> [ Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears ]
• Installation position of locking collar/synchronizer hub--> [ Installation Position of Locking Collar/Synchronizer Hub for 3rd and 4th Gear ]
• Pressing on --> [ Pressing On Synchronizer Hub with Locking Collar for 3rd and 4th Gears ]
25 Circlip
26 Synchronizer ring for 3rd gear
• Checking for wear --> [ Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear ]
27 Outer race for 3rd gear
• Insert into synchronizer ring --> [ (item 26) Synchronizer ring for 3rd gear ] , installation position --> [ Installed Location of Outer Race for 1st and 3rd Gear ]
• Replace if grooved or scored
28 Synchronizer ring
• (Inner race for 3rd gear)
• Checking for wear --> [ Checking Inner Race for 1st Gear, 2nd Gear and 3rd Gear for Wear ]
• Checking tabs for scoring
• Installed location --> [ Installation Location of Synchronizer Ring (Inner Race for 1st and 3rd Gear) ]
29 Needle bearing
• For 3rd gear
30 Selector gear for 3rd gear
• Installed location --> [ Installation Position of Selector Gear for 1st and 3rd Gear ]
31 Tapered roller bearing inner race
• Pulling off --> [ Pulling Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
32 Circlip
• When replacing tapered roller bearing --> [ 31 Tapered roller bearing inner race ] and output shaft --> [ 6 Output shaft ] , determine again --> [ Determining Circlip ]
33 Tapered roller bearing outer race
• Pulling out --> [ Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing ]
• Pressing in --> [ Pressing Outer Race/Tapered Roller Bearing
into Transmission Housing ]
34 Shim
• Determining thickness --> [ Output Shaft, 1st through 4th Gears, Adjusting ] Output Shaft, 1st through 4th Gears, Adjusting.
35 Transmission housing
Pull Dished Washer - A - Out of Output Shaft
Pressing Dished Washer in Output Shaft to Stop
Pulling Out Tapered Roller Bearing Outer Race
A Support, e.g. (Kukko 22/2)
B Internal puller 56 to 70 mm, e.g. (Kukko 21/8)
Pressing Outer Race/Tapered Roller Bearing into Clutch Housing
- Support clutch housing directly beneath bearing mount using sleeve (40 - 20).
Pulling Off Inner Race/Tapered Roller Bearing
- Remove circlip beforehand.
- Before attaching extractor, place pressure piece (VW 431) in output shaft and place thrust pad (40 - 105).
Pulling Off Synchronizer Hub/Locking Collar for 3rd and 4th Gear with Selector Gear for 4th Gear
- Remove circlip beforehand.
A Extractor, e.g. (Kukko 18/2)
B Separating device 22 to 115 mm, e.g. (Kukko 17/2)
Pressing Off Locking Collar and Synchronizer Hub for 1st and 2nd Gears
After removing circlip, press off selector gear for 2nd gear and locking collar/synchronizer hub together.
Pressing Off Inner Race/Tapered Roller Bearing
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
Pressing On Inner Race/Tapered Roller Bearing
Checking Inner Race for 1st Gear, 2nd Gear and 3rd Gear for Wear
- Press inner race onto cone of selector gear and measure gap dimension - a - using a feeler gauge.
Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear
- Press synchronizer ring, outer race and inner race onto cone of selector gear and measure gap dimension - a - using a feeler gauge.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- Place inner race - A - on selector gear for 2nd gear.
The bent tabs - arrow 1 - face toward outer race - B -.
- Install outer race - B -.
Tabs - arrows 2 - engage in grooves - arrows 3 - of selector gear.
- Install synchronizer ring - C -.
The grooves - arrows 4 - engage in tabs - arrows 1 - of inner race - A -.
Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as Well as 3rd and 4th Gears
1. Spring
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 for 1st and 2nd Gears as Well as 3rd and 4th Gears
The locking collar is pushed over synchronizer hub.
- Insert locking pieces and install springs 120 degrees offset. Spring must engage with angled end into hollow engaging piece.
Installation Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
The identification groove - arrow 1 - and thin collar - arrow 2 - of synchronizer hub points to 1st gear.
Pressing On Locking Collar/Synchronizer Hub for 1st and 2nd Gear
- Install circlip.
Installed Location of Outer Race for 1st and 3rd Gear
Tabs - arrows - point to synchronizer hub/operating sleeve - A -.
Installation Location of Synchronizer Ring - A - (Inner Race for 1st and 3rd Gear)
Tabs - arrows 1 - engage into cut outs - arrows 2 - of synchronizer ring - B -.
Installation Position of Selector Gear for 1st and 3rd Gear
The higher collar - A - points to 2nd and 4th gear - B -. Recesses in collar - arrows - engage into outer race tabs --> [ Installed Location of Outer Race for 1st and
3rd Gear ]
Installation Position of Locking Collar/Synchronizer Hub for 3rd and 4th Gear
Wider collar of synchronizer hub - arrow - points to 3rd gear.
Pressing On Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Install circlip.
Checking Synchronizer Ring for 4th Gear for Wear
- Press synchronizer ring onto cone of selector gear and measure gap dimension - a - using a feeler gauge.
Pressing On Inner Race/Tapered Roller Bearing
- Determine circlip --> [ Determining Circlip ] and install.
Determining Circlip
- Determine thickest circlip which can still just be installed and insert.
- Determine circlip according to table.
Available Circlips
Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing
A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
Pressing Outer Race/Tapered Roller Bearing into Transmission Housing
- Insert shim under outer race.
- Support transmission housing beneath bearing mount using pressure piece (2050).