Output Shaft: Service and Repair

Special tools, testers and auxiliary items required:
^ Multi-purpose tool 771/1 with attachment 771/15
^ Installing sleeve 2003/3
^ Punch 3013
^ Thrust pad 3062
^ Thrust piece 3118
^ Drift 3138
^ Drift VW295
^ Thrust plate VW401
^ Thrust plate VW402
^ Press tool VW407
^ Press tool VW411
^ Press tool VW 412
^ Tube VW415a
^ Support rails VW457
^ Separating device 22-1 1 5mm (e.g. Kukko1 7/2)
^ Internal puller 12-14.5mm (e.g. Kukko22/1)
^ Hot air blower V.A.G1416

Notes:
^ When installing new gears or final drive set, see Technical data.
^ Adjustments are required when replacing components marked 1).





1. Gearbox housing
^ Servicing
2. Shim "S3"
^ Adjustment overview
3. Outer race for large taper roller bearing 1)
^ Pulling out see Fig. 1
^ Pressing in see Fig. 2 and Fig. 3
4. Drive pinion 1)
^ Paired with crown wheel (final drive set)
5. Needle bearing for flange shaft/drive pinion
^ Pulling out see Fig. 4
^ Driving in see Fig. 5
6. Inner race for large taper roller bearing 1)
^ Pressing off see Fig. 6
^ Pressing on see Fig. 7
^ Low friction bearing; do not oil when measuring friction torque
7. Circlip
^ Redetermining see Fig. 8
8. Flange ring
^ Installation position
9. Tapered rollers
^ Qty. 23
^ Installation position
10. Support ring
^ Installation position
11. Corrugated spring
12. Needle - bearing for drive pinion/hollow shaft
^ Oil before installing
13. Hollow shaft with 3rd and 4th speed gears 1)
14. Needle bearing for 2nd speed sliding gear
^ Split
^ Oil with gear oil before installing
15. 2nd speed sliding gear
^ Pressing off
^ Before installing, fit spring and slide needle bearing onto hollow shaft
^ After installing, check axial clearance with a feeler gauge (0.15 - 0.35 mm)
16. Synchroring for 2nd gear
^ Coated with Molybdenum
^ Checking for wear
17. Synchrohub for 1st and 2nd gear
^ Pressing off see Fig. 12
^ Pressing on see Fig. 13
^ Installation position: flush hub towards 2nd speed sliding gear
18. Circlip
^ Removing and installing see Fig. 11
^ Redetermining see Fig. 8
19. Washer
^ Removing and installing see Fig. 11
20. Locking collar for 1st and 2nd gear
^ Installation position: splines for reverse gear towards synchro ring for 2nd gear
21. Synchroring for 1st gear
^ Checking for wear
22. Needle bearing for 1st speed sliding gear
^ Oil with gear oil before installing
23. 1st speed sliding gear
^ Before installing, insert spring
^ After pressing on -item 24 -, check axial clearance
24. Inner race for small taper roller bearing 1)
^ Pressing off see Fig. 9
^ Pressing on see Fig. 10
^ Low friction bearing; do not oil when measuring friction torque
25. Outer race for small taper roller bearing 1)
^ Driving out see Fig. 15
^ Pressing in see Fig. 16
26. Shim "S4"
^ Adjustment overview
27. Bearing plate 1)
^ Servicing
28. 6th gear wheel
^ Pressing off
^ Pressing on
^ Installation position: shoulder towards inner race for small taper roller bearing
29. Spacer sleeve
30. Shim
^ Redetermining
31. 5th gear wheel
^ Pulling off
^ Driving on
32. Circlip for 5th gear wheel
^ Redetermining
33. End cover
^ Servicing4





Fig. 1 Pulling out outer race for large taper roller bearing
^ Stepped side of thrust pad 3062 rests against the outer race





Fig. 2 Heating gearbox housing to insert the outer race for large taper roller bearing
- Heat gearbox housing in area of bearing seat for approx. 15 minutes, to approx. 100°C, with a hot air blower.





Fig. 3 Inserting outer race for large taper roller bearing in gearbox housing and pressing home
- Insert outer race only after heating gearbox housing and press home for 1-2 minutes under a repair press until a heat exchange has taken place.





Fig. 4 Pulling out needle bearing for flange shaft/drive pinion
A- Internal puller 12-14.5 mm, e.g. Kukko 21/1





Fig. 5 Driving needle bearing for flange shaft/ drive pinion in flush





Fig. 6 Pressing off inner race for large taper roller bearing
A - Separating device 22-115 mm, e.g. Kukko 17/2
^ Bearing is destroyed when pressing off





Fig. 7 Pressing on inner race for large taper roller bearing
- Heat inner race to approx. 100°C and fit.
- Press home ensuring there is no axial play.





Fig. 8 Determining circlip for large taper roller bearing for drive pinion
- Determine the thickest circlip that can still just be fitted.
- Determine circlip from table. Part numbers





The following circlips are available:
- Fit circlip.





Fig. 9 Pressing off inner race of small taper roller bearing for drive pinion together with 1st speed sliding gear

Note: Do not press off together with 1st and 2nd gear synchro-hub and 2nd speed sliding gear.





Fig. 10 Pressing on inner race for small taper roller bearing for drive pinion together with 1st speed sliding gear
- Install circlip, shim for 1st speed sliding gear, synchro-ring for 1st speed, and 1st speed sliding gear with spring and needle bearing.
- Heat inner race to approx. 100°C and fit.
- Press home ensuring there is no axial play.

Notes:
^ With shoulder of thrust piece 3118 facing downwards, press only onto bearing inner race.
^ Position stepped shoulder of tube VW 415 A facing up towards press tool VW 412.
^ After pressing on, check axial clearance of 1st speed sliding gear.





Fig. 11 Removing and installing circlip for synchro-hub and shim for 1st speed sliding gear
- Removing, take off shim -A- then circlip -B-.
- Installing, fit circlip -B- then shim -A-.





Fig. 12 Pressing off 2nd speed sliding gear with synchrohub for 1st and 2nd gear
- Take off locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
- Remove shim and circlip for synchrohub.
- Press off 2nd speed sliding gear together with synchro-hub for 1st and 2nd gear.

Note: Do not press off together with 1st speed sliding gear and inner race for small taper roller bearing.





Fig. 13 Fitting 2nd speed sliding gear, pressing on synchrohub for 1st and 2nd gear
- Install needle bearing (split), sliding gear with spring and synchro-ring for 2nd gear.
- Oil needle bearing.
- Heat synchro-hub to approx. 100°C and fit.
- Press home ensuring there is no axial play.

Notes:
^ Position tube VW415 a with shoulder towards synchro-hub.
^ Position thrust pad 3118 with stepped shoulder towards press tool VW 412.





Fig. 14 Determining thickness of circlip for synchro-hub for 1st and 2nd gear
- Determine the thickest circlip that can still just be fitted.
- Determine circlip from table. Part No.





The following circlips are available:
- Fit circlip in direction of arrow onto synchro-hub.





Fig. 15 Driving out outer race for small taper roller bearing





Fig. 16 Pressing in outer race for small taper roller bearing
- Insert shim "S4" into bearing flange behind bearing seat.
- Position stepped shoulder of thrust pad 3062 towards press tool VW407.
- Press outer race for small taper roller bearing onto stop.