Output Shaft
Output Shaft
Special tools, testers and auxiliary items required
• Thrust Plate (VW 402)
• Punch (VW 407)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Arbor 50 mm Dia. (VW 432)
• Press Tube (30 - 100)
• Kukko Extractor 30-37 mm (21/5)
• Kukko Support (22/1)
• Inductive Heater (VAS 6414)
• When installing new gears or a new input shaft, refer to => [ Codes Letters, Transmission Allocation and Capacities ] Codes Letters, Transmission Allocation and Capacities and the Parts Catalog.
• Insert all bearings, selector gears and synchronizer rings on the output shaft using transmission fluid.
• Do not exchange synchronizer rings, always allocate to original selector gear when reusing.
• Wearing safety gloves, warm the bearing inner races, the gear wheels and the synchronizer hubs to approximately 100 °C (212 °F) using the (VAS 6414) before installing them.
1 Clutch Housing
2 Cylindrical Roller Bearing
• With lock ring
• Removing.
• Installing.
• Installed position: Lock ring in bearing points to output shaft.
3 Output Shaft
• With bearing inner race for the cylindrical roller bearing.
• The bearing inner race cannot be removed from the output shaft.
• If there are grooves or damage on the bearing inner race on the cylindrical roller bearing, then replace both the output shaft and cylindrical roller bearing.
4 4th Gear
• Installed position: The shoulder faces the 3rd gear.
5 Lock Ring
• Always replace damaged or stretched lock rings.
6 Lock Ring
• Always replace damaged or stretched lock rings.
7 3rd Gear
• Installed position: The shoulder faces the 4th gear.
8 Lock Ring
• Always replace damaged or stretched lock rings.
9 2nd Gear
10 Needle Bearing
• For the 2nd gear.
11 2nd Gear Inner Race
• Checking for wear.
• Installed position.
12 2nd Gear Outer Race
• Lay on inner race - item 11 -.
• Replace if there are grooves or scoring.
• Installed position.
13 2nd Gear Synchronizer Ring
• Checking for wear.
• Installed position.
14 Locking Collar with Synchronizer Hub for 1st and 2nd Gears
• After removing the lock ring - item 15 -, remove with the 2nd gear.
• Disassembling.
• Assembling the locking collar/synchronizer hub.
• Installed position.
• Installing.
15 Lock Ring
• Press out.
• Installing.
16 1st Gear Synchronizer Ring
• Checking for wear.
• Insert it so that the holes engage into the engagement pieces of locking collar - item 14 -.
17 1st Gear Outer Race
• Install into the synchronizer ring - item 16 -, installed position.
• Replace if there are grooves or scoring.
18 1st Gear Inner Race
• Checking for wear.
• Check for scoring.
• Installed position.
19 Needle Bearing
• For the 1st gear.
20 1st Gear
• Installed position.
21 Bearing Mount with Grooved Ball Bearing
• Only replace the grooved ball bearing together with the bearing mount.
• If the bearing mount is removed from the transmission housing, it must always be replaced.
• Removing, refer to => [ Removing the Bearing
Mount and Grooved Ball Bearing ] Input Shaft.
• Installing, refer to => [ Installing the Bearing
Mount with Grooved Ball Bearing ] Input Shaft.
22 Transmission Housing
23 5th Gear
• Installed position: The collar faces the transmission housing cover. Refer to => [ Installed Position
of the 5th Gear: ] Transmission.
24 Lock Ring
• Always replace
• Determining thickness, refer to => [ Select a new lock ring. ] Transmission.
25 Spring
• Installed position.
26 Locking Collar
27 Synchronizer Hub
28 Locking Pieces
• Quantity: 3
Removing the Roller Bearing from the Clutch Housing
- Compress the cylindrical roller bearing lock ring - arrow - with pliers - C - and remove it.
A Counter-support, for example, (22/1)
B Internal puller 30 to 37 mm, for example, (21/5)
Pressing the Cylindrical Roller Bearing into the Clutch Housing
- Support the clutch housing using the (VW 415 A) (not illustrated) directly below bearing mount.
- Compress the cylindrical roller bearing lock ring - arrow - with pliers - A - and install it.
- Remove the pliers before the cylindrical roller bearing gets into its installed position. The lock ring must lock into the groove on the clutch housing.
Removing the Lock Ring - 1 -
A Protective gloves
CAUTION!
Prevent the lock ring from jumping away uncontrolled.
Locking Collar/Synchronizer Hub for 1st and 2nd Gear
- After removing the lock ring, remove the selector gear for 2nd gear and the locking collar/synchronizer hub.
Installed Location of 3rd and 4th Gear Drive Gears
- Install the 4th gear - A - onto the output shaft.
Installed position:
The collar - arrow 1 - faces the 3rd gear - B -.
- Install the lock rings - 2 and 3 -.
- Install the 3rd gear - B - on the output shaft.
Installed position:
The collar - arrow 2 - faces the 4th gear - A -.
- Install the lock ring - 1 -.
Checking the Inner Race for 1st Gear and 2nd Gear for Wear
- Install the inner race onto the taper of the selector gear and then measure the gap dimension - a - with a feeler gauge.
Checking 1st Gear and 2nd Gear Synchronizer Ring 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.
Installed Position: 2nd Gear Outer Race, Inner Race and Synchronizer Ring
- 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 Synchronizer Hub for 1st and 2nd Gears
1. Spring
2. Locking collar
3. Synchronizer hub
4. Locking piece
- Slide the locking collar over the synchronizer hub.
Installed position:
The groove on the front - arrow A - and the higher collar - arrow B - on the synchronizer hub faces the outer splines on the locking collar - arrow C -.
Deeper recesses - arrow D - for the locking pieces in the synchronizer hub and recesses - arrow E - in locking collar must align.
Assembling the Locking Collar/Synchronizer Hub for 1st and 2nd Gears
• The locking collar is pushed over the synchronizer hub.
- Insert the locking pieces in the deeper recesses - arrows - and install the springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.
Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears
Installed position:
The shift fork groove in the locking collar faces 1st gear and the reverse gear splines face 2nd gear.
- Turn the synchronizer ring so that the grooves line up with the locking pieces.
Lock Ring Installing
- Place the 1st gear synchronizer ring in the locking collar/synchronizing hub.
Installed Position of the 1st Gear Outer Race
Tabs - arrows - face the reverse gear splines
1st Gear Inner Race - A - Installed Position
The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.
Installed Location of the 1st Gear Selector Gear
The higher collar - A - faces the 2nd gear - B -. The recesses inside the collar - arrows - engage into the tabs on the outer race (- arrow -, refer to ).