Disassembly and Assembly

Input Shaft

Special tools, testers and auxiliary items required

• Pressure plate (VW 401)

• Pressure plate (VW 402)

• Punch (VW 412)

• Sleeve (VW 415 A)

• Alignment fixture (T10356/6)

• Alignment fixture (T40088/2)

• Inductive heater (VAS 6414)

• Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.

• Before installing the roller bearing inner races, warm to a maximum of 100 ? while wearing protective gloves.

• Warm synchronizer ring before pressing off to a maximum of 100 °C while wearing protective gloves.

• Always press the roller bearing inner race and synchronizer hub all the way on so that the gear wheels have the specified axial play.

• Input shaft removed, refer to => [ Transmission, Assembly Sequence ] Disassembly and Assembly

Removing the synchronizer hub with the 3rd and 4th gear locking collar





• Mark the installation position.

- Remove the thrust washer, gear wheel, needle bearing and 4th gear synchronizer rings.

- Remove circlip.

- Remove the synchronizer hub with the 3rd and 4th gear locking collar.

- Remove the synchronizer ring, gear wheel and 3rd gear needle bearing.

Removing the locking ring - A - and side thrust washers - B -





Removing the thrust ring - 2 - and 5th and 6th gear synchronizer hub locking ring - 1 -





- Remove the gear wheel, needle bearing and 6th gear synchronizer rings.

Removing the synchronizer hub with the 5th and 6th gear locking collar





• Mark the installation position.

- Remove the synchronizer hub and locking collar with the 5th gear wheel.

Pressing on synchronizer hub with locking collar for 5th and 6th gears





• The thrust plate (VW 401) must be under the 2nd gear wheel.

Installation position, 5th and 6th gear synchronizer hub locking ring - 1 - and thrust ring - 2 -





• The groove - arrow - all the way around faces the locking ring - 1 -.

Installing the locking ring - A - and two-piece thrust washer - B -





- Install the synchronizer rings, needle bearings and the 6th gear wheel.

- Install thrust washers - B - so that both tabs fit into the holes in the shaft.

- Install the locking ring - A -.

- Install the needle bearing, the gear wheel and the 3rd gear synchronizer rings.

Pressing on synchronizer hub with locking collar for 3rd and 4th gears





• The thrust plate (VW 401) must be under the 2nd gear wheel.

- Install securing ring.

- Install the synchronizer rings, needle bearing, 4th gear wheel and thrust washer.