Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
Special tools, testers and auxiliary items required
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Sleeve (VW 519)
• Thrust Pad (3002)
• Shop Press (V.A.G 1290A)
• - 1 -Two-Arm Puller (Kukko 20/10)
• - 1 -Two-Arm Puller (Kukko 20-20) with Hooks 300 mm
• Gearbox Support (T40206)
• Assembly Tool (T40213)
• Inductive heater (VAS 6414)
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Removing
- Attach the plate (T40213/1) to the (T40206) using the bolts - arrows -.
- Insert the adapter (T40213/5) and (T40213/6) into the plate (T40213/1).
• Secure the adapter (T40213/5) and (T40213/6) with knurled bolts (T40213/3) after installing the shafts.
- Install the input shaft - 1 - together with the output shaft - 2 - and the shift fork group into the adapter (T40213/5) and (T40213/6).
• If it is necessary to disassemble the input shaft, then the bolt - A - in the shaft must be removed now using, for example, a torque wrench - D -.
• Shift 2 gears over the locking collars - B - and - C - in direction of - arrow -.
• The shafts must be in vertical position.
- Then shift the locking collars back into the neutral position.
• Slightly turn the output shaft clockwise so that the locking collars - B - and - C - can be shifted back into the center position. Install the bolt - 2 - => [ Bolt ] Output Shaft Assembly Overview back into the output shaft in order to turn the shaft.
- Remove the bolts - arrows - and remove the shift fork group from the bearing bracket.
- Remove the 1st gear wheel - B - with the reverse gear synchronizer hub and the reverse gear wheel inner race.
A Two arm puller, for example (Kukko 20/10) or (Kukko 20-20)
Danger of causing damage to the clutch splines on the 1st gear wheel - B -
• The hooks on the two-arm puller must not touch the clutch splines on the 1st gear wheel.
- Remove the 1st/2nd gear synchronizer hub locking ring
- Remove the 2nd gear wheel - B -, the synchronizer hub and the 1st/2nd gear locking collar.
A Two-arm puller, for example, (Kukko 20-20) with 300 mm hooks
- Remove the bearing bracket from the input and output shafts.
• Output shaft, disassembling and assembling, refer to => [ Output Shaft ] Output Shaft.
• Input shaft, disassembling and assembling, refer to => [ Input Shaft ] Input Shaft.
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Installing on the Output Shaft
- Install the plate (T40213/1) with the adapters (T40213/5) and (T40213/6) on the (V.A.G 1290A) table.
- Install the output shaft - 1 - and input shaft - 2 - in the adapter (T40213/5) and (T40213/6).
- Install the bearing bracket over both shafts - 3 -; the plastic part - 4 - faces upward.
Installation Position: 1st and 2nd Gear Synchronizer Rings
• If the components are not to be replaced, make sure they are reallocated to their original gear.
- Place inner race - 2 - on sliding gear - 1 -.
- Install intermediate ring - 3 -. Tab - B - must be inserted into recess - A -.
- Insert synchronizer ring - 4 -. Guide tabs - C - through recess - arrow -.
- Install the 2nd gear wheel, the needle bearing and the synchronizer rings - A -. Place close attention to the position of the synchronizer rings.
• The tabs - arrows - on the synchronizer rings must fit into the openings on the synchronizer hub when installing the 1st/2nd gear synchronizer hub.
Installing the 1st/2nd Gear Synchronizer Hub
• Heat the synchronizer hub to approximately 100 °C (212° F).
• Synchronizer hub installed position: the higher inside collar is facing the 2nd gear wheel.
• Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.
- Install the 1st/2nd gear synchronizer hub locking ring.
• When replacing the synchronizer hub or the output shaft:
Determine the locking ring - 1 - for the 1st/2nd gear synchronizer hub.
- Determine thickest circlip which can still just be installed and insert it. For the part number, refer to the electronic parts catalog ETKA
The following locking rings are available:
- Install the 1st gear wheel, the synchronizer rings and the needle bearings on the output shaft.
- Install the thrust washer - A - and then install the heated inner race - B - for the reverse gear needle bearing.
- Install the reverse gear needle bearing, the gear wheel and the reverse gear locking collar => [ Installed Position: Locking
Collar and Reverse Gear Wheel ] Output Shaft Assembly Overview.
- Install the reverse gear synchronizer ring in the locking collar.
- Heat the reverse gear synchronizer hub to approximately 100 °C (212° F).
- Install the reverse gear synchronizer hub - A - with the spring installed - 7 -=> [ Spring ] Output Shaft Assembly Overview.
• The tabs - arrow - on the synchronizer ring must lock into the openings in the reverse gear synchronizer hub.
- Attach the plate (T40213/1) to the (T40206) using the bolts - arrows -.
- Secure the shift fork group - A - to the bearing bracket - C - with the bolts - B -.
• The bolt - A - inside the input shaft must be tightened now with a torque wrench - D - to the tightening specification - 36 -=> [ Bolt ] Input Shaft Assembly Overview if the input shaft was disassembled and assembled again. Clean the thread on the bolt with a wire brush and then install it with locking fluid (AMV 185 101 A1).
• Shift 2 gears over the locking collars - B - and - C - in direction of - arrow -.
• The shafts must be in vertical position.
- Then shift the locking collars back into the neutral position.
• Turn the input shaft by the bolt - A - slightly counter-clockwise so that the locking collars - B - and - C - can be shifted again into the center position.
- Remove the input shaft, the output shaft and the shift fork group from the plate (T40213/1).