Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts
Special tools, testers and auxiliary items required
• Thrust Disc (VW 412)
• Tube 60 mm Dia. (VW 415 A)
• Thrust Pad (VW 447 H)
• Thrust Piece (40 - 105)
• Tube (3296)
• Shop Press (V.A.G 1290A)
• Inductive Heater (VAS 6414)
• Gearbox Support (T40206)
• Assembly Tool (T40213)
• Two-Arm Puller (Kukko 20/10)
• Extraction Hook 200 mm
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Removing
- Attach the plate (T40213/1) to the (T40206) using the bolts - arrows -.
- Insert the adapter (T40213/6) and (T40213/7) into the plate (T40213/1).
• Use knurled bolts (T40213/3) to mount the adapter after installing the in- and output shafts.
- Install the input shaft - 1 - together with the output shaft - 2 - and the shift fork group into the - 3 - in the adapter (T40213/6) and (T40213/7).
- Remove the bolts - arrows - and remove the shift fork group from the bearing bracket - 4 -.
- Remove the thrust washer - A -, reverse gear synchronizer hub - B - and reverse gear wheel - C -.
- Remove the 1st gear wheel - E - along with the inner race/needle bearing for reverse gear - C - and the thrust washer - D -.
A Two-arm puller , for example, (Kukko 20/10)
B Extraction hook 200 mm
Danger of causing damage to the clutch splines on the 1st gear wheel - B -.
• The hooks on the two-arm puller must not touch the clutch splines on the 1st gear wheel.
- Remove the 2nd gear wheel - E - along with the inner race/needle bearing for 1st gear - C - and the synchronizer hub/locking collar - D -.
A Two-arm puller , for example, (Kukko 20/10)
B Extraction hook 200 mm
- Remove the needle bearing - 1 -.
- Remove the bearing bracket - 2 - from the input - 4 - and output shafts - 3 -.
• Output shaft, disassembling and assembling, refer to => [ Output Shaft ] Output Shaft.
• Input shaft, disassembling and assembling, refer to => [ Input Shaft ] Input Shaft.
Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts, Installing on the Output Shaft
- Install the plate (T40213/1) with the adapters (T40213/6) and (T40213/7) on the (V.A.G 1290A) table.
- Install the output shaft - 1 - and input shaft - 2 - in the adapter (T40213/6) and (T40213/7).
- In the installed position, mount the bearing bracket over both shafts - 3 -, and the raised surfaces - arrows - face upward.
Installation location of Synchronizer Rings for 1st, 2nd and Reverse Gears
• If the parts are not to be replaced, make sure they are reallocated to their original gear.
- Place inner race - 2 - on selector gear - 1 -.
- Install the intermediate ring - 3 -. The tab - B - must be inserted into the recess - A -.
- Insert synchronizer ring - 4 -. Guide the tabs - C - through the recess - arrow -.
- Insert 2nd gear wheel together with needle bearing and synchronizer rings.
Installing the Synchronizer Hub with Locking Collar for 1st and 2nd Gears
• Heat the synchronizer hub to approximately 100 °C (212 °F).
• Note the locking collar/synchronizer hub installed location; refer to => [ Assembly of Locking Collar/Synchronizer
Hub for 1st and 2nd Gears ] Output Shaft Overview.
• Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.
Heat the Inner Race/Needle Bearing - A - for 1st Gear Wheel up to Approximately 100 °C (212 °F) and Install.
- Install the 1st gear wheel - A -, the synchronizer rings and the needle bearings on the output shaft.
- Mount the thrust washer - B - and install the heated inner race - C - for the needle bearing reverse gear wheel.
- Mount the reverse gear wheel - C - with needle bearing and reverse gear locking collar.
- Mount the reverse gear synchronizer hub - B - along with the synchronizer rings and thrust washer - A -.
- Mount the plate (T40213/1) on the (T40206).
- Clean bolt threads - arrows - with a wire brush. Next, coat the bolts with locking compound (AMV 185 101 A1).
- Secure the shift fork group - 3 - to the bearing bracket - 4 - with the bolts - arrows -.
- Remove the input shaft - 1 - together with the output shaft - 2 - and the shift fork group from the plate (T40213/1).