Bearing plate, servicing: Notes

Fig 1: Identifying Special Tools - Gear Carrier, Servicing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and equipment 

• VW 408 A Press tool
• 10-15 Guide pins
• 30-504 Press tool
• 1 - Kukko 21/3 Internal puller

• 4 - Kukko 22/1 Counter support
• Depth gauge

Fig 2: Gear Carrier, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bearing plate 

• Re-determine shim S4 when replacing

2 - Outer race/small taper roller bearing for drive pinion 

• Driving out. Refer to Driving out outer race for small taper roller bearing 
• Pressing in. Refer to Pressing in outer race/small taper roller bearing 
• Re-determine shim S4 when replacing

3 - Shim S4 

• Adjustment overview. Refer to Adjustment overview 
• Re-determining thickness. Refer to Re-determining shim S4 

4 - Cylinder roller bearing for input shaft 

• Pressing out. See Pressing cylinder roller bearing for input shaft out of bearing plate 
• Pressing in. See Pressing cylinder roller bearing for input shaft into bearing plate 
• Measuring insertion depth. See Measuring insertion depth of cylinder roller bearing for input shaft 

Fig 3: Gear Carrier, Overview

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5 - Ball sleeves 

• 4 pieces
• Removing and driving in. See Driving out and driving in ball sleeves for selector rods 

For follower for reverse gear:

• Pulling out. See Pulling ball sleeve out of follower for reverse gear 
• Tapping in. See Driving ball sleeve flush into follower for reverse gear 

6 - Bolt, 35 Nm 

• For relay lever

7 - Dowel pin (7 x 28) 

• Drive in and drive out with drift

8 - Reverse idler gear 

• For reverse gear

9 - Reverse gear synchro-ring 

• With locking pins
• Checking for wear. See Checking synchro-ring for wear 
• Installation position: Position flat on synchro-ring circumference to face input shaft. Refer to Figure

Fig 4: Gear Carrier, Overview

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10 - Spring 

• Installation position: Hook single angled end into recess on synchro-ring. Turn double angled end anti-clockwise and insert into opening on bearing plate

11 - Reverse idler gear axle 

12 - Retaining plate 

• Installation position: Chamfers of holes for locking pins of synchro-ring face bearing plate. Refer to Figure

13 - Spring clasp 

14 - Bolt, 25 Nm 

• Self-locking
• Always replace

Fig 5: Gear Carrier, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

15 - Relay lever for reverse gear 

16 - Follower for reverse gear 

• Pulling out ball sleeve. See Pulling ball sleeve out of follower for reverse gear 
• Driving in ball sleeve. See Driving ball sleeve flush into follower for reverse gear 

17 - Selector rod for 5th and 6th gear 

• Replace only together with follower. Refer to 5th and 6th gear, removing and installing , Item 6