Output Shaft, 1st to 4th Gears
Output Shaft, 1st to 4th Gears
=> [ Differences in Synchronizing 1st/2nd Gears ]
=> [ Assembling the Output Shaft for 1st through 4th Gears, through Transmission Build Date 25 October 2009 ]
=> [ Assembling the Output Shaft for 1st through 4th Gears, from Transmission Build Date 26 October 2009 ]
The 1st/2nd gear synchronizing was changed as of 26 October 2009. Refer to => [ Differences in Synchronizing 1st/2nd Gears ].
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408A)
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415A)
• 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 540/1B)
• Taper Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Kukko Extractor 46-58 mm (21/7)
• Kukko Extractor (Kukko 21/8)
• Kukko Puller 80-210 mm (Kukko 18/2)
• Kukko Separating Tool 22-115 mm (Kukko 17/2)
• Kukko Support (Kukko 22/2)
Pull Dished Washer - A - out of Output Shaft
Pressing Dished Washer into Output Shaft
Dimension "a" = 2 mm
Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
A Separating device 22 to 115 mm, for example, (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 Support, for example, (22/2)
B Internal puller 56 to 70 mm, for example, (21/8)
Pressing Outer Race/Tapered Roller Bearing into Clutch Housing
- Support the clutch housing directly beneath the bearing mount using the (40-20).
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 (VW 431) in the output shaft and lay the (40-105).
Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
- Determine the circlip and install.
Determining the Circlip
- Determine the thickest circlip which can still just be installed - and insert.
The following circlips are available:
Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing
A Support, for example, (22/2)
B Internal puller 46 to 58 mm, for example, (21/7)
Pressing Outer Race/Tapered Roller Bearing into Transmission Housing
- Install the shim under the outer race.
- Support the transmission housing beneath the bearing mount using the (2050).
Output Shaft, Disassembly
• Removing the inner race/tapered roller bearing on the side of the clutch housing.
Pulling off Synchronizer Hub/Operating Sleeve for 3rd and 4th Gear with Gear Wheel for 4th gear
- Remove the circlip beforehand.
A Extractor, for example, (18/2)
B Separating device 22 to 115 mm, for example, (17/2)
Pressing off Locking Collar and Synchronizer Hub for 1st and 2nd Gears
After removing the circlip, press off selector gear for 2nd gear and locking collar/synchronizer hub together.
Differences in Synchronizing 1st/2nd Gears
Synchronizing 1st/2nd Gear, to Transmission Build Date 25 October 2009
Synchronizing 1st/2nd Gear, from Transmission Build Date 26 October 2009
Assembling the Output Shaft for 1st through 4th Gears, through Transmission Build Date 25 October 2009
Checking Inner Race for 1st, 2nd and 3rd Gears for Wear
- Check the tabs on the inner race for scoring.
- Press the inner race onto the taper of the selector gear and measure the gap dimension - a - using a feeler gauge.
Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear
- Press the synchronizer ring, outer race and inner race onto the taper of the selector gear and measure the gap dimension - a - using a feeler gauge.
- Install the 2nd gear wheel with needle bearing.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- 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.
- Place the inner race - A - on the 2 gear wheel.
The bent tabs - arrow 1 - face toward the outer race - B -.
- Install the outer race - B -.
The tabs - arrow 2 - engage in the grooves - arrows 3 - of the gear wheel.
- Install the synchronizer ring - C -.
The grooves - arrow 4 - engage in the tabs - arrow 1 - of the inner race - A -.
Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 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 recesses for the locking pieces in the synchronizer hub and locking collar must align.
Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears as well as 3rd and 4th Gears
The locking collar is pushed over the synchronizer hub.
- Insert the locking pieces and install the springs 120° offset. The spring must engage with the angled end into the hollow engaging piece.
Installed Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
The identification groove - arrow 1 - and thin collar - arrow 2 - of the synchronizer hub point to 1st gear.
Pressing on Locking Collar/Synchronizer Hub for 1st and 2nd Gear
Turn the synchronizer ring so that the grooves align with the locking pieces.
- Install the circlip.
Install the synchronizer ring for 1st gear.
Installed Position of 1st Gear Outer Race
The tabs - arrows - point to the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (1st Gear Inner Race)
The tabs - arrows 1 - engage into the recesses - arrows 2 - of the synchronizer ring - B -.
Install 1st Gear Wheel with Needle Roller Bearing
The higher collar - A - faces toward the 2nd gear - B -. Recesses in the collar - arrows - engage into the outer race tabs.
- Install the thrust washers - item 19 - => [ Thrust Washers ] Output Shaft, 1st to 4th Gears Overview and - item 20 -=> [ Washer ] Output Shaft, 1st to 4th Gears Overview for 1st and 4th gears.
- Install the 4th gear wheel with the needle bearing.
Checking Synchronizer Ring for 4th Gear for Wear
- Press the synchronizer ring onto the taper of the gear wheel and measure the gap dimension - a - using a feeler gauge.
Installed Position of Locking Collar/Synchronizer Hub for 3rd and 4th Gear
The wider collar of the synchronizer hub - arrow - points to 3rd gear.
Pressing on Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the synchronizer ring so that the grooves align with the locking pieces.
- Install the circlip.
- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.
Installed Position: 3rd Gear Outer Race
The tabs - arrows - point to the synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (3rd Gear Inner Race)
The tabs - arrows 1 - engage into the recesses - arrows 2 - of the synchronizer ring - B -.
Installed Position: 3rd Gear Wheel
The higher collar - A - faces toward the 4th gear - B -. Recesses in the collar - arrows - engage into the outer race tabs.
- Install the 3rd gear wheel with the needle bearing.
• Pressing on the inner race/tapered roller bearing.
• Determining the locking ring for the inner race/tapered roller bearing.
Assembling the Output Shaft for 1st through 4th Gears, from Transmission Build Date 26 October 2009
Checking the Inner Contact Surface for Wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- Install the inner race - 1 - on the cone on the gear wheel.
- Install the outer race - 2 - on the cone on the inner race. Measure the gap - a - with a feeler gauge at 3 locations 120° apart.
- Note the average value.
Checking the Outer Contact Surface for Wear on the 1st Gear Outer Race and on the 2nd Gear Outer Race
- Check the synchronizer ring - arrow - on the inner running surface for grooves and radial wear, and replace if necessary.
- Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.
- Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.
- Measure the gap - a - with a feeler gauge at 3 locations 120° apart.
- Note the average value.
- Install the 2nd gear wheel with needle bearing.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- Install the inner race - A - in the gear wheel.
The tabs - 1 - face away from the gear wheel.
- Install the outer race - B -.
The tabs - 2 - engage in the grooves - 3 - on the gear wheel.
- Install the synchronizer ring - C -.
The larger openings - 4 - lock in the tabs - 1 - on the inner race - A -.
Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 3rd and 4th Gears
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- Slide the locking collar over the synchronizer hub.
On the 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.
The recesses for the locking pieces in the synchronizer hub and locking collar must align.
Assembling Locking Collar/Synchronizer Hub for 1st and 2nd Gears as well as 3rd and 4th Gears
The locking collar is pushed over the synchronizer hub.
- Insert the locking pieces and install the springs 120° offset. The spring must engage with the angled end into the hollow engaging piece.
Installed Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
The identification groove - arrow 1 - and thin collar - arrow 2 - of the synchronizer hub point to 1st gear.
Pressing on Locking Collar/Synchronizer Hub for 1st and 2nd Gear
The pins - A - on the synchronizer ring lock into the recesses - B - in the synchronizer hub.
- Install the circlip.
Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race
- Install the synchronizer ring - A - in the synchronizer hub.
The tabs - 1 - lock in the openings - 2 - in the synchronizer hub.
- Install the outer race - B - in the synchronizer ring.
The tabs - 3 - face away from the synchronizer ring.
- Install the inner race - C - in the outer race.
The tabs - 4 - lock in the larger openings - 5 - in the synchronizer ring - A -.
Install 1st Gear Wheel with Needle Roller Bearing
• The synchronizer ring - 1 - and the tabs - arrow A - are inside the openings in the synchronizer hub - 2 -.
The pins - arrows B - in the outer race lock in the recesses - arrows C - in the gear wheel - 3 -.
- Install the thrust washers - item 19 - => [ Thrust Washers ] Output Shaft, 1st to 4th Gears Overview and - item 20 -=> [ Washer ] Output Shaft, 1st to 4th Gears Overview for 1st and 4th gears.
- Install the 4th gear wheel with needle bearing.
Checking Synchronizer Ring for 4th Gear for Wear
- Press the synchronizer ring onto the taper of the gear wheel and measure the gap dimension - a - using a feeler gauge.
Installed Position of Locking Collar/Synchronizer Hub for 3rd and 4th Gear
Wider collar of synchronizer hub - arrow - points to 3rd gear.
Pressing on Synchronizer Hub with Locking Collar for 3rd and 4th Gears
- Turn the synchronizer ring so that the grooves align with the locking pieces.
- Install the circlip.
Checking the 3rd Gear Inner Race for Wear
- Press the inner race onto the taper of the selector gear and measure the gap dimension - a - using a feeler gauge.
Checking Synchronizer Ring for 3rd Gear for Wear
- Press the synchronizer ring, outer race and inner race onto the taper of the selector gear and measure the gap dimension - a - using a feeler gauge.
- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.
Installed Position: 3rd Gear Outer Race
Tabs - arrows - point to synchronizer hub/locking collar - A -.
Installed Position: Synchronizer Ring - A - (3rd Gear Inner Race)
The tabs - arrows 1 - engage into the recesses - arrows 2 - of the synchronizer ring - B -.
Installed Position: 3rd Gear Wheel
The higher collar - A - faces toward the 4th gear - B -. Recesses in the collar - arrows - engage into the outer race tabs.
- Install the 3rd gear wheel with the needle bearing.