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)

Remove the Small Outer Race/Tapered Roller Bearing

A Internal puller 37 to 46 mm, for example, Kukko extractor 37-46 mm (21/6)
B Counter support, for example, Kukko support (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 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 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
B 17 mm, M10 x 20 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 Support

- Remove the lock ring - arrow - first.

Removing the Inner Race/Large Tapered Roller Bearing

A - Jaw protectors

- Before installing the 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.

- 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 the Inner Races for 1st and 2nd Gears for Wear

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

Checking the 1st and 2nd 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.

Disassembly and Assembly of the 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 the 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 the 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°. 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°. 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 the 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 the 2nd Gear Outer Race ].

Installing the Sleeve for the 3rd Gear Needle Bearing

Checking the 3rd/4th Gear Synchronizer Ring for Wear

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

Disassembly and Assembly of the 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 the 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°. 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