Overview - Output Shaft
Pay attention to the technical data when installing new gears or the output shaft. Refer to TECHNICAL DATA .
Insert all needle bearings and synchronizer rings with transmission fluid.
When replacing synchronizer rings, the intermediate ring and synchronizer ring for the respective gear must be replaced together.
If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
- Cap
- With oil guide
- For the output shaft
- Removing and installing. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .
- Bolt
- 200 Nm
- For the output shaft
- Coat with Locking Fluid AMV 185 101 A1
- If necessary warm the bolt with the Hot Air Blower VAG1416 to 80°C to loosen it.
- Transmission Housing
- Ball Bearing
- For the output shaft
- Removing and installing. Refer to OVERVIEW - TRANSMISSION HOUSING -item 15- (See illustration 73). .
- Circlip
- Installation position. Refer to Figure.
- Reverse Gear Synchronizer Hub
- Removing and installing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING .
- Synchronized Spring
- Insert into the hole on the reverse gear synchronizer hub. Refer to Figure.
- Reverse Gear Synchronizer Ring
- Checking for wear. Refer to Fig 3
- Reverse Gear Locking Collar
- Installed position. Refer to Fig 2.
- Reverse Gear Wheel
- Installed position. Refer to Fig 2.
- Needle Bearing
- For reverse gear
- Inner Race/Needle Bearing
- For reverse gear
- Removing and installing. Refer to WHEEL SET, DISASSEMBLING AND ASSEMBLING .
- Thrust Washer
- For 1st gear and reverse gear selector gears
- 1st Gear Wheel
- 1st Gear Inner Race
- Intermediate Ring for 1st Gear
- Synchronizer Ring for 1st Gear
- Needle Bearing
- For 1st gear
- Circlip
- Selecting thickness. Refer to chart (See Figure).
- Thrust Piece
- Quantity: 3
- Installing. Refer to Fig 7.
- Synchronizer Hub for 1st and 2nd Gears
- Installation position. Refer to Fig 7
- Locking Collar for 1st and 2nd Gear
- Installation position. Refer to Fig 7
- Synchronizer Ring for 2nd Gear
- 2nd Gear Intermediate Ring
- 2nd Gear Inner Race
- 2nd Gear Wheel
- Needle Bearing
- For 2nd gear
- Bearing Bracket
- Supports input shaft and input shaft in transmission cover
- Refer to -item 3- "Bearing Bracket".
- Roller Bearing
- Output Shaft
- With splines for 5th and 6th gears
- Needle Bearing or Bearing Bushing
- 3rd Gear Wheel
- Spacer Sleeve
- 4th Gear Wheel
- Circlip
- Selecting thickness. Refer to Figure .
- Transmission Cover
- Spur Gear
- With tapered roller bearing and gear carrier
- Spur Gear Bearing, Servicing. Refer to OVERVIEW - SPUR GEAR FOR BEARING AND CENTER DIFFERENTIAL
- The pointed teeth -arrow A- in the locking collar -2- face opposite the reverse gear selector gear drive splines -arrow B- -1-.
-- Press the synchronizer ring -E- into the locking collar and then measure the gap dimension -a- using a depth gauge -D- at -A-, -B- and -C-.
-- Add the measured values and then divide the sum by 3.
The value must not be greater than 0.5 mm.
-A- the friction surface on the inside of the 1st gear inner race has a coating -arrow 1- and is conical.
-B- there is no friction surface on the inside of the 2nd gear inner race -arrow 2- and is cylindrical.
-- Check the outer friction surface -arrow- for scoring or signs of wear, replace if necessary.
-- Press inner race onto gear wheel taper and measure gap dimension -a- using a Feeler Gauge.
| Gap dimension -a- | Wear limit |
|---|---|
| 1st gear - inner race | 0.6 mm |
-- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
-- Place inner race, intermediate ring and synchronizer ring on selector gear taper and >>turn<<.
>>Turn<< means: turn the synchronizer rings just about one turn while pressing on the rings at the same time.
-- Then measure the gap dimension -a- with a feeler gauge.
| Gap dimension -a- | Wear limit |
|---|---|
| 1st and 2nd gear | 0.7 mm |
Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
-- Mount the locking collar -1- over the synchronizer hub -2- so that the wire tooth spacing on the locking collar -arrow A- and on the synchronizer hub -arrow B- align with each other.
- Synchronizer hub installed position: the higher inside collar -arrow C- is facing the 2nd gear wheel.
-- Then place thrust pieces -3- in synchronizer hub and press thrust pieces into notches -arrows D- in locking collar.