Output Shaft For 5TH, 6TH and Reverse, Disassemble and Assemble
Output shaft for 5th, 6th and reverse gear, disassembling and assembling
Special tools and equipment
^ VW401 Thrust plate
^ VW 402 Thrust plate
^ VW 407 Press tool
^ VW 408 A Press tool
^ VW 412 Press tool
^ VW 415 A Tube
Special tools and equipment
^ VW 309 Holding plate
^ VW 353 Transmission support
^ VW 433 Press piece
^ VW 454 Press piece
^ VW 457 Support rail
^ VW 801 Holding plate
Special tools and equipment
^ VW 431 Press piece
^ VW 455 Fitting sleeve
^ VW 510 Press piece
^ VW516Tube
^ VW519 Tube
^ 30-11 Thrust plate
Special tools and equipment
^ 40-105 Thrust plate
^ 40-20 Press tool
^ 2050 Thrust piece
^ 3235 Press
^ 3296 Tube
Special tools and equipment
^ V.A.G 1582 Tapered roller bearing puller
^ V.A.G. 1582/4 Grip
^ V.A.G 1582/7 Grip
^ 1-Kukko 21/7 Internal puller
^ 3-Kukko 17/2 Separating device
^ 4-Kukko 22/2 Counter support
Note:
^ When installing new gears or a new output shaft consult technical data, Refer to Manual Transmission Transaxle, Application and ID
^ If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment, Refer to Output Shaft For 5TH, 6TH and Reverse Gear, Adjusting.
1- Clutch housing
2- Shim
^ Always 0.65 mm thick
3- Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
4- Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 8
^ Pressing on, Refer to Fig. 20
5- Output shaft
6- Reverse gear synchro-hub
^ Pressing off, Refer to Fig. 7
^ Installation position - Fig. 9
^ Pressing on, Refer to Fig. 10
7- Securing clip
8- Reverse gear locking collar
^ Securing clip
9- Needle roller bearing
^ For reverse gear
10- Reverse sliding gear
11- Sleeve
^ Press off with reverse gear, Refer to Fig. 6
^ Installation position: wide shoulder of sleeve faces toward reverse gear
^ Pressing on, Refer to Fig. 11
12- Securing clip
13- Needle roller bearing
^ For 6th gear
^ Not in 5-speed manual transmissions
14- 6th gear
^ Not in 5-speed manual transmissions
15- 6th gear synchro-ring
^ Not in 5-speed manual transmissions
^ Checking for wear, Refer to Fig. 12
16- Spacer sleeve
^ For 5-speed manual transmission
^ Pull off together with 5th gear locking collar/synchro-hub after removing securing clip (item - 18 -), Refer to Fig. 5
^ Position toward 5th gear locking collar/synchro-hub, Refer to Fig. 16
^ Press on together with 5th gear locking collar/synchro-hub, Refer to Fig. 17
17- 5th and 6th gear locking collar with synchro-hub
^ After removing securing clip, press off together with 6th gear (item -18-) or for 5-speed manual transmission, with spacer sleeve
^ Disassembling, Refer to Fig. 13
^ Assembling locking collar/synchro hub, Refer to Fig. 13 and Fig. 13
^ Pressing off in 6-speed manual transmission, Refer to Fig. 15
^ Pressing off in 5-speed manual transmission, Refer to Fig. 17
18- Securing clip
19- Needle roller bearing
^ For 5th gear
2- 5th gear synchro-ring
^ Check for wear, Refer to Fig. 12
21- Selector gear for 5th gear
22- Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 18
23- Securing clip
^ Redetermine if tapered roller bearing (item -22-) or output shaft (item -5-) are replaced, Refer to Fig. 19
24- Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 21
^ Pressing in, Refer to Fig. 22
25- Shim
26- Transmission housing
27- Spring
^ Installation position, Refer to Fig. 14
28- Locking collar
29- Synchro-hub
30- Locking pieces (Qty. 3)
^ Installation position, Refer to Fig. 13
Fig. 1 Pulling tapered roller bearing outer race out from transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Note:
After pressing out, check washer for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into transmission housing
^ Install washer under outer race.
^ Support transmission housing with press tool 40-20 directly below bearing mounting.
Fig. 3 Pulling off tapered roller bearing inner race
^ Before mounting extractor, position press piece VW 431 and thrust plate 40-105 on output shaft.
Fig. 4 Pressing off 5th and 6th gear synchro-hub/locking collar with 6th gear
Fig. 5 Pressing off 5th gear synchro-hub/locking collar with spacer sleeve
Fig. 6 Pressing off sleeve -A- over reverse gear wheel
Fig. 7 Pressing off reverse gear synchro-hub
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 8 Pulling off tapered roller bearing inner race
^ Before mounting extractor, set thrust plate 30-11 on output shaft.
Fig. 9 Installation position of reverse gear synchro-hub
Reverse gear locking collar stop (arrow -A-) faces toward toothing of output shaft (arrow -B-).
Fig. 10 Pressing on reverse gear synchro-hub
Fig. 11 Pressing on sleeve
Installation position: Wide collar faces toward reverse gear.
Fig. 12 Checking synchro-ring for wear
^ Press synchro-ring onto gear cone and measure gap "a" with feeler gauge.
Fig. 13 Disassembling and assembling 5th and 6th gear locking collar and synchro-hub
1- Spring
2- Locking piece
3- Locking collar
4- Synchro-hub
^ Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.
Fig. 14 Assembling 5th and 6th gear locking collar/synchro-hub
The locking collar has been pushed over the synchro-hub.
^ Insert locking pieces and install springs 120° offset. Angled end of spring must locate in hollow locking piece.
Fig. 15 Pressing on 5th and 6th gear locking collar/synchro-hub
Fig. 16 Positioning spacer sleeve toward 5th gear locking collar/synchro-hub
Lugs (arrow -1-) of spacer sleeve must line up with recesses in synchrohub (arrow -2-).
Lock pieces (arrow -3-) must rest on collar of spacer sleeve.
Fig. 17 Pressing on 5th gear locking collar/synchro-hub together with spacer sleeve
Fig. 18 Pressing on tapered roller bearing inner race
Fig. 19 Determining thickness of circlip
^ Determine thickest circlip which will still fit and install it.
The following securing clips are available:
Fig. 20 Pressing on tapered roller bearing inner race
Fig. 21 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Fig. 22 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press piece 2050 directly below bearing support.