Part I
Output Shaft, 1st to 4th Gears
=> [ Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization ]
=> [ Assembling, through Transmission Build Date 25 October 2009 ]
=> [ Assembling, from Transmission Build Date 26 October 2009 through 24 May 2010 ]
=> [ Assembling, from Transmission Build Date 25 May 2010 ]
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)
• Holding Fixture (VW 313)
• Transmission Support (VW 353)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Thrust Pad (VW 512)
• Tube 42 mm Dia. (VW 516)
• Sleeve (VW 519)
• Slide Hammer-Complete Set (VW 771)
• Holding Fixture (VW 801)
• Thrust Piece (40-105)
• Sleeve (40-20)
• Sleeve (40-21)
• Thrust Plate (2050)
• Spacers (VW 540/1 B)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Inductive Heat Unit (VAS 6414)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor (21/8)
• Kukko Puller 80-210 mm (18/2)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
Removing the Concave Washer - A - from the Output Shaft
Installing the Concave Washer onto the Output Shaft
Dimension - a - = 2 mm
Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
A Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing
A Counter support, for example, Kukko support (22/2)
B Internal puller 56 to 70 mm, for example, Kukko puller 80-210 mm (21/8)
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Support the clutch housing using the sleeve (40-20) directly under the bearing mount.
Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
Before installing the tapered roller bearing puller:
- Remove the inner race/tapered roller bearing lock ring on the side facing the clutch housing.
- Mount the thrust pad 16.5/28 mm dia. (VW 431) in the output shaft and lay the thrust piece (40-105).
Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
- Choose the correct lock ring, refer to => [ Selecting the Lock Ring ] and install it.
Selecting the Lock Ring
- Choose and install the thickest lock ring that will fit.
• For the correct lock rings, refer to the Parts Catalog.
The following lock rings are available:
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
- Install the adjusting shim under the outer race.
- Support the transmission housing under the bearing mount using the thrust plate (2050).
Disassembling the Output Shaft
• Removing the inner race/tapered roller bearing on the side of the clutch housing. Refer to => [ Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing ].
Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear
- Remove the lock ring beforehand.
A Puller, for example, Kukko puller 80-210 mm (18/2)
B Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
- Remove the washers for 1st and 4th gears - items 19 and 20 - in the => [ 1st to 4th Gears Output Shaft Overview ] 1st to 4th Gears Output Shaft Overview
- Remove the 1st gear - item 18 - in the => [ 1st to 4th Gears Output Shaft Overview ] 1st to 4th Gears Output Shaft Overview.
Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear
After removing the lock ring, press off the selector gear for 2nd gear and the locking collar/synchronizer hub together.
Differentiating 1st/2nd Gear Synchronization, Differentiating 3rd Gear Synchronization
1st/2nd Gear Synchronization through Transmission Build Date 25 October 2009 and 3rd Gear Synchronization through Transmission Build Date 24 May 2000
1st/2nd Gear Synchronization from Transmission Build Date 26 October 2009 and 3rd Gear Synchronization from Transmission Build Date 25 May 2000
Assembling, through Transmission Build Date 25 October 2009
Checking the Inner Race for 1st, 2nd and 3rd Gears for Wear
- Check the tabs on the inner race for scoring.
- Install the inner race onto the taper of the selector gear and then measure the gap dimension - a - with a feeler gauge.
Checking the 1st, 2nd and 3rd Gear Synchronizer Rings for Wear
- Install the synchronizer ring, outer race and inner race onto the taper of the selector gear and then measure the gap dimension - a - with a feeler gauge.
- Install the 2nd gear with the needle bearing.
Installed Position: 2nd Gear Outer Race, Inner Race and Synchronizer Ring
- Check the tabs - arrows 1 and 2 - for scoring.
- Replace the inner race, the outer race and the synchronizer ring if they have grooves or scoring.
- Install the inner race - A - on the 2nd gear.
The angled tabs - arrows 1 - face the outer race - B -.
- Install the outer race - B -.
The tabs - arrows 2 - must lock into the retainers - arrows 3 - in the gear.
- Install the synchronizer ring - C -.
The retainers - arrows 4 - lock in the tabs - arrows 1 - on the inner race - A -.
Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.
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 1st, 2nd, 3rd and 4th 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.
Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears
The identification groove - arrow 1 - and the narrow collar - arrow 2 - on the synchronizer hub face 1st gear.
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.
- Install the lock ring.
Install the 1st gear synchronizer ring
Installed Position of the 1st Gear Outer Race
The tabs - arrows - face the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (1st Gear Inner Race)
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
Installing the 1st Gear with Needle Roller Bearing
The higher collar - A - faces 2nd gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position of the 1st Gear Outer Race ].
- Install the thrust washers (- items 19 and 20 - in the => [ 1st to 4th Gears Output Shaft Overview ] 1st to 4th Gears Output Shaft Overview) for 1st and 4th gears.
- Install the 4th gear with needle bearing.
Checking the 4th Gear Synchronizer Ring for Wear
- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.
Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears
The wider collar on the synchronizer hub - arrow - faces 3rd gear.
Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
- Install the lock ring.
- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.
Installed Position: 3rd Gear Outer Race
The tabs - arrows - face the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (3rd Gear Inner Race)
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
Installed Position: 3rd Gear
The higher collar - A - faces toward 4th gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position of the 1st Gear Outer Race ].
- Install the 3rd gear with the needle bearing.
• Pressing on the inner race/tapered roller bearing. Refer to => [ Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing ].
• Selecting the lock ring for the inner race/tapered roller bearing. Refer to => [ Selecting the Lock Ring ].
Assembling, from Transmission Build Date 26 October 2009 through 24 May 2010
Checking the Inner Contact Surface for Wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- Install the inner race - 1 - on the cone on the gear.
- Install the outer race - 2 - on the cone on the inner race. Measure the gap - a - with a feeler gauge at 3 locations at 120°.
- Note the average value.
Checking the Outer Contact Surface for wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- Check the synchronizer ring - arrow - on the inner running surface for grooves and radial wear, and replace if necessary.