Part 1
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 2000 ]
=> [ Assembling, from Transmission Build Date 25 May 2000 ]
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)
• 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
- 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 extractor (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 locking 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 locking ring, refer to => [ Selecting the Locking Ring ] and install.
Selecting the Locking Ring
- Choose and install the thickest locking ring that will fit.
• For the correct locking rings, refer to the Parts Catalog.
The following locking 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 locking 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)
Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear
After removing the circlip, press off the selector gear for the 2nd gear and 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 Gear 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.
Continued, Part 2