Output Shaft, 1st to 4th Gears
Output Shaft, 1st to 4th 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)
• Spacers (VW 540/1 B)
• Sleeve (40 - 20)
• Sleeve (40 - 21)
• Thrust Plate (2050)
• Tapered Roller Bearing Puller (V.A.G 1582)
• Grip (V.A.G 1582/7)
• Kukko extractor 21/7 and 21/8
• Puller 18/2
• Separating tool 17/2
• Kukko 22/2 counter-support
Pull Dished Washer - A - Out of Output Shaft
Pressing Dished Washer in Output Shaft to Stop
• Dimension - a - = 2 mm
Pulling Out Tapered Roller Bearing Outer Race
A Support, for example (Kukko 22/2)
B Internal puller 56 to 70 mm, for example (Kukko 21/8)
Press the Outer Ring for the Tapered Roller Bearing into the Clutch Housing
- Support clutch housing directly beneath bearing mount using (40 - 20).
Pulling off Inner Race for Tapered Roller Bearing
- Remove circlip.
- Before attaching extractor, place (VW 431) and (40 - 105) on input shaft.
Pulling Off Synchronizer Hub/Operating Sleeve for 3rd and 4th Gear with Gear Wheel for 4th Gear
- Before pulling off, remove circlip.
A Extractor, for example (Kukko 18/2)
B Separating device 22 to 115 mm, for example (Kukko 17/2)
Pressing Off Locking Collar and Synchronizer Hub for 1st and 2nd Gears
- Remove circlip.
- Press off selector gear and locking collar/synchronizer hub all together.
Pressing Off Inner Race for Tapered Roller Bearing
A Separating device 22 to 115 mm, for example (Kukko 17/2)
Pressing on Tapered Roller Bearing Inner Race
Checking Inner Race for 1st gear, 2nd Gear and 3rd Gear for Wear
- Press inner race onto taper of gear wheel and measure gap dimension - a - using a feeler gauge.
Checking Synchronizer Rings for 1st, 2nd and 3rd Gears for Wear
- Press synchronizer ring, outer race and inner race onto taper of gear wheel and measure gap dimension - a - using a feeler gauge.
Installed Position of Outer Race, Inner Race and Synchronizer Ring, 2nd Gear
- Place inner race - A - on the 2 gear wheel.
• The bent tabs - arrow 1 - face toward outer race - B -.
- Install outer race - B -.
• The tabs - arrows 2 - engage in the gear wheel grooves - arrows 3 -.
- Install synchronizer ring - C -.
• The grooves - arrows 4 - engage in the tabs - arrows 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
- Remove the springs to disassemble - 1 -.
1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer hub
- To assemble, slide 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.
• Installed position: the narrow recesses in the synchronizer hub align with the recesses in the locking collar.
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 locking pieces and install the springs 120° offset.
• Spring must engage with angled end into hollow engaging piece.
Installation Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gear
• The identification groove - arrow 1 - and thin collar - arrow 2 - of synchronizer hub point to 1st gear.
Pressing on locking Collar/Synchronizer Hub for 1st and 2nd Gear
- Then install circlip.
Installation Position of Outer Ring for 1st and 3rd Gear
• Tabs - arrows - point to synchronizer hub/locking collar - A -.
Installed Position of Synchronizer Ring - A - (inner ring for 1st and 3rd gear)
• Tabs - arrows 1 - engage into cut-outs - arrows 2 - of synchronizer ring - B -.
Installation Position of Selector Gear for 1st and 3rd Gear
• The higher collar - A - points to 2nd and 4th gear - B -. Recesses in collar - arrows - engage into outer race tabs.
Installation 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
- Then install circlip.
Checking Synchronizer Ring for 4th Gear for Wear
- Press synchronizer ring onto taper of the gear wheel and measure gap dimension - a - using a feeler gauge.
Pressing on Tapered Roller Bearing Inner Race
- Determine circlip and install.
Determining Circlip
- 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:
Pulling Outer Race/Tapered Roller Bearing Out of Transmission Housing
A Support, for example (Kukko 22/2)
B Internal puller 46 to 58 mm, for example (Kukko 21/7)
Pressing in Tapered Roller Bearing Outer Race into Transmission Housing
- Install shim under outer race.
- Support transmission housing beneath bearing mount using (2050).