Bearing housing, servicing: Notes

Fig 1: Identifying Special Tools - Bearing Housing, Servicing (1 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Thrust plate VW 402
• Press tool VW 408 A
• Thrust disc VW 412
• Thrust tube VW 454

• Installing sleeve VW 455
• Tube 42 mm dia. VW 516

Fig 2: Identifying Special Tools - Bearing Housing, Servicing (2 Of 2)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required 

• Guide pin 10 - 15
• Thrust pad 3074
• - 1  - Internal puller Kukko 21/2
• - 4  - Counter-support Kukko 22/1

• Drift T40085

Fig 3: Bearing Housing Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bearing housing

• Re-determine shim "S₄ " when replacing → Re-determining shim "S4" when replacing bearing housing 

2 - Outer race

• For needle roller bearing on input shaft
• Driving out Driving outer race for needle roller bearing out of bearing housing 
• Pressing in Pressing outer race for needle roller bearing into bearing housing until limit stop 

3 - Shim "S₄ "

• Table of adjustments → Table of adjustments 
• Re-determine when replacing bearing housing → Re-determining shim "S4" when replacing bearing housing 

4 - Tapered roller bearing outer race

• For output shaft

5 - Selector rod for 1st and 2nd gear

• Only replace together with selector fork for 1st and 2nd gear (secured together by means of a pin)

6 - Reverse gear selector rod

7 - Ball sleeve

• (Front) for reverse gear selector rod
• Pulling out Pulling front ball sleeve out of reverse gear selector rod 
• Pressing in Pressing front ball sleeve into reverse gear selector rod until limit stop. 

8 - Ball sleeve

• (Rear) for reverse gear selector rod
• Pulling out Pulling out rear ball sleeve for reverse gear selector rod 
• Pressing in Pressing in rear ball sleeve - A - for reverse gear selector rod 

9 - Selector rod for 3rd and 4th gear

10 - Selector rod for 5th and 6th gear

• Remove burrs and scoring after removing from bearing housing

11 - Ball sleeve

• For selector rod for 5th and 6th gear
• Pull out with internal puller Kukko 21/2
• Drive in until flush using guide pin 10 - 15

12 - Locking bushing

• For selector rod for 3rd and 4th gear
• Removing and installing Removing and installing locking bushing for selector rod 

13 - Locking bushing

• For selector rod for 5th and 6th gear
• Removing and installing Removing and installing locking bushing for selector rod 

14 - Ball sleeve

• For selector rod for 3rd and 4th gear
• Pull out with internal puller Kukko 21/2
• Driving in Driving in ball sleeve for selector rod for 3rd and 4th gear