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 60 mm Dia. (VW 415 A)
• Holding Plate (VW 309)
• Transmission Support (VW 353)
• Thrust Pad Con. 8/65 (VW 433)
• Thrust Tube (VW 454)
• Support Channels (VW 457)
• Holding Fixture (VW 801)
• Thrust Pad 16.5/28 mm Dia. (VW 431)
• Thrust Tube (VW 455)
• Thrust Pad (VW 510)
• Tube 42 mm Dia. (VW 516)
• Sleeve (VW 519)
• Thrust Pad (30-11)
• Thrust Piece (40-105)
• Sleeve (40-20)
• Thrust Plate (2050)
• Tube (3296)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Attachment to VAG 1582 (V.A.G 1582/4)
• Grip (V.A.G 1582/7)
• Inductive Heat Unit (VAS 6414)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Separating Tool 22-115 mm (17/2)
• Kukko Support (22/2)
Removing the Outer Race/Tapered Roller Bearing
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)
• Check the washer for damage after removing it and replace if necessary.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
- Place the washer under the outer race.
- Support the clutch housing using the sleeve (40-20) directly under the bearing mount.
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
- Support the transmission housing under the bearing mount using the thrust plate (2050).
Disassembling the Output Shaft
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 transmission housing.
- Mount the thrust pad 16.5/28 mm dia. (VW 431) and the thrust piece (40-105) on the output shaft.
Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar and the 6th Gear
- Remove the lock ring beforehand.
Removing the Sleeve - A - together with the Reverse Gear
- Remove the lock ring beforehand.
Removing the Reverse Gear Synchronizer Hub
- Remove the lock ring beforehand.
A Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm (17/2)
Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
- Mount the thrust pad (30-11) on the output shaft before removing the puller.
Assembling the Output Shaft
• Heat the tapered roller bearing inner races and synchronizer hub to approximately 100 °C (212 °F) with a heat gun before installing. Press on to the stop when installing, so there is no axial clearance.
Installed Position: Reverse Gear Synchronizer Hub
• The stop - arrow A - on the reverse gear locking collar faces the splines on the output shaft - arrow B -.
Heating and Installing the Reverse Gear Synchronizer Hub
- Install the lock ring.
- Mount the reverse gear locking collar on the reverse gear synchronizer hub.
- Install the reverse gear and the needle bearing.
Installing the Sleeve - A -
• Installed position: The wide collar points toward the reverse gear selector gear.
- Install the lock ring.
Checking the 5th and 6th 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.
Disassembling and Assembling the Locking Collar and Synchronizer Hub for 5th and 6th Gears
- To disassemble, remove the springs - 1 -.
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
• Installed position: The narrow locking piece recesses in the synchronizer hub align with the recesses in the locking collar.
Assembling the Locking Collar/Synchronizer Hub for 5th and 6th 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.
- Install the 6th gear with needle bearing.
- Install the 6th gear synchronizer ring.
Heating and Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears
On some locking collars, there is a chamfer on the outer diameter.
Installed position: The chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear
- Turn the 6th gear synchronizer ring so that the grooves line up with the locking pieces.
- Install the lock ring.
- Install the 5th gear synchronizer ring.
- Install 5th gear selector gear with needle bearing.
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.
- Select the lock ring according to the table. For the correct part number, refer to the Parts Catalog.
Available Lock Rings
Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
