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 (VW 415 A)
• Holding plate (VW 309)
• Transmission support (VW 353)
• Thrust pad con. (VW433)
• Thrust tube (VW 454)
• Support channels (VW 457)
• Holding fixture (VW 801)
• Thrust pad 16.5/28 mm dia. (VW431)
• Thrust tube (VW 455)
• Thrust pad (VW 510)
• Tube (VW 516)
• Tube (VW 519)
• Thrust piece (30 - 11)
• Thrust piece (40 - 105)
• Seal driver-frt wheel bearing (40 - 20)
• Thrust plate (2050)
• Tube (3296)
• Taper roller bearing puller (V.A.G 1582)
• Attachment (V.A.G 1582/4)
• Attachment (V.A.G 1582/7)
• Internal extractor (Kukko 21/7)
• 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, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
• Always replace both taper roller bearings together as a set.
1 Clutch housing
2 Washer
• Always 0.65 mm thick
3 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 ]
4 Tapered roller bearing inner race
• Pulling off --> [ Pulling Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
5 Output shaft
• For 5th/6th and reverse gears
• Adjusting --> [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
6 Synchronizer hub for reverse gear
• Pressing off --> [ Pressing Off Synchronizer Hub for Reverse Gear ]
• Installed location --> [ Installed Location of Synchronizer Hub for Reverse Gear ]
• Pressing on --> [ Pressing On Synchronizer Hub for Reverse Gear ]
7 Circlip
8 Locking collar for reverse gear
• With synchronizer ring
9 Needle bearing
• For gear wheel for reverse gear
10 Selector gear for reverse gear
11 Sleeve
• Pressing off over reverse gear selector gear --> [ Pressing Off Sleeve over Reverse Gear Selector Gear ]
• Installation position: Wider collar on sleeve points toward reverse gear selector gear
• Pressing on --> [ Press On Sleeve ]
12 Circlip
13 Needle bearing
• For 6th gear
14 Selector gear for 6th gear
15 Synchronizer ring for 6th gear
• Checking for wear --> [ Checking Synchronizer Ring for 5th and 6th Gears for Wear ]
16 Locking sleeve with synchronizer hub for 5th and 6th gears
• After removing circlip --> [ (item 17) Circlip ] , press off with selector gear for 6th gear --> [ Pressing Off Synchronizer Hub/Locking Collar for 5th and 6th Gears with Selector Gear for 6th Gear ]
• Disassembling --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears ]
• Assembling operating sleeve/synchronizer hub --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears ] and --> [ Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears ]
• Pressing on --> [ Pressing On Locking Collar/Synchronizer Hub for 5th and 6th Gears ]
17 Circlip
18 Needle bearing
• For 5th gear
19 Synchronizer ring for 5th gear
• Checking for wear --> [ Checking Synchronizer Ring for 5th and 6th Gears for Wear ]
20 Selector gear for 5th gear
21 Tapered roller bearing inner race
• Pulling off --> [ Pulling Off Inner Race/Tapered Roller Bearing ]
• Pressing on --> [ Pressing On Inner Race/Tapered Roller Bearing ]
22 Circlip
• When replacing tapered roller bearing --> [ 21 Tapered roller bearing inner race ] and output shaft --> [ 5 Output shaft ] , determine again--> [ Determining Circlip ]
23 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 ]
24 Shim
• Determining thickness --> [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
25 Transmission housing
26 Spring
• Installed location --> [ Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears ]
27 Locking collar
28 Synchronizer hub
29 Locking pieces (Qty. 3)
• Installed location --> [ Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears ]
Pulling Out Tapered Roller Bearing outer Race
A Support, e.g. (Kukko 22/2)
B Internal puller 46 to 58 mm, e.g. (Kukko 21/7)
• After pulling off, check shim for damage and replace if necessary.
Pressing Outer Race/Tapered Roller Bearing into Clutch Housing
- Insert shim under outer race.
- 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 thrust piece (VW 431) and thrust plate (40 - 105) on output shaft.
Pressing Off Synchronizer Hub/Locking Collar for 5th and 6th Gears with Selector Gear for 6th Gear
- Remove circlip beforehand.
Pressing Off Sleeve - A - over Reverse Gear Selector Gear
- Remove circlip beforehand.
Pressing Off Synchronizer Hub for Reverse Gear
- Remove circlip beforehand.
A Separating device 22 to 115 mm, e.g. (Kukko 17/2)
Pulling Off Inner Race/Tapered Roller Bearing
- Before installing puller, set thrust piece (30 - 11) onto output shaft.
Installed Location of Synchronizer Hub for Reverse Gear
Stop - arrow A - for reverse gear locking collar points toward output shaft splines - arrow B -.
Pressing On Synchronizer Hub for Reverse Gear
- Install circlip.
Press On Sleeve - A -
Installation position: Wide collar faces toward reverse gear selector gear.
- Install circlip.
Checking Synchronizer Ring for 5th and 6th Gears for Wear
- Press synchronizer ring onto cone of selector gear and measure gap dimension - a - using 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 locking collar over synchronizer hub.
The recesses for locking pieces in synchronizer hub and locking collar must align.
Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears
The locking collar is pushed over synchronizer hub.
- Insert engaging pieces and install springs at 120 degrees offset. Spring must engage with angled end into hollow engaging piece.
Pressing On Locking Collar/Synchronizer Hub for 5th and 6th Gears
- Install circlip.
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
Pressing On Inner Race/Tapered Roller Bearing
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
- Support transmission housing beneath bearing mount using pressure piece (2050).