Shift Fork Group, Input Shaft, 1ST, 2ND And Reverse Gear Output Shafts: Notes

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Special tools and workshop equipment required

Thrust Disc VW 412
Tube 60 mm Dia. VW 415 A
Sleeve VW 519
Thrust Pad 3002
Shop Press V.A.G 1290A
-1- Two-Arm Puller Kukko 20/10
-1- Two-Arm Puller Kukko 20-20 with Hooks 300 mm
Gearbox Support T40206
Assembly Tool T40213
Inductive heater VAS 6414

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-.

Fig 1: Attaching Plate T40213/1 To T40206 Using Bolts

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-- Insert the adapter T40213/5 and T40213/6 into the plate T40213/1.

NOTE:

Secure the adapter T40213/5 and T40213/6 with knurled bolts T40213/3 after installing the shafts.

-- Install the input shaft -1- together with the output shaft -2- and the shift fork group into the adapter T40213/5 and T40213/6.

Fig 2: Installing Input Shaft Together With Output Shaft And Shift Fork Group Into Adapter T40213/5 And T40213/6

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If it is necessary to disassemble the input shaft, then the bolt -A- in the shaft must be removed now using, for example, a torque wrench -D-.

Fig 3: Shifting 2 Gears Over Locking Collars -B- And -C- In Direction Of -Arrow-
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Shift 2 gears over the locking collars -B- and -C- in direction of -arrow-.
The shafts must be in vertical position.

-- Then shift the locking collars back into the neutral position.

NOTE:

Slightly turn the output shaft clockwise so that the locking collars -B- and -C- can be shifted back into the center position. Install the bolt -2- OUTPUT SHAFT ASSEMBLY OVERVIEW back into the output shaft in order to turn the shaft.

-- Remove the bolts -arrows- and remove the shift fork group from the bearing bracket.

Fig 4: Removing Bolts -Arrows- And Remove Shift Fork Group From Bearing Bracket

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-- Remove the 1st gear wheel -B- with the reverse gear synchronizer hub and the reverse gear wheel inner race.

Fig 5: Removing 1St Gear Wheel -B- With Reverse Gear Synchronizer Hub And Reverse Gear Wheel Inner Race

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A - Two arm puller, for example Kukko 20/10 or Kukko 20-20

CAUTION:

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 1st/2nd gear synchronizer hub locking ring

-- Remove the 2nd gear wheel -B-, the synchronizer hub and the 1st/2nd gear locking collar.

Fig 6: Removing 2Nd Gear Wheel Synchronizer Hub And 1St/2Nd Gear Locking Collar

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A - Two-arm puller, for example, Kukko 20-20 with 300 mm hooks

-- Remove the bearing bracket from the input and output shafts.

NOTE:

Output shaft, disassembling and assembling, refer to OUTPUT SHAFT .

Input shaft, disassembling and assembling, refer to 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 T40213/5 and T40213/6 on the V.A.G 1290 A table.

Fig 7: Installing Plate T40213/1 With Adapters T40213/5 And T40213/6 On V.A.G 1290 A Table

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-- Install the output shaft -1- and input shaft -2- in the adapter T40213/5 and T40213/6.

-- Install the bearing bracket over both shafts -3- ; the plastic part -4- faces upward.

Installation Position: 1st and 2nd Gear Synchronizer Rings

Fig 8: Installation Position Of Synchronizer Rings For 1St And 2Nd Gear

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NOTE:

If the components are not to be replaced, make sure they are reallocated to their original gear.

-- Place inner race -2- on sliding gear -1-.

-- Install intermediate ring -3-. Tab -B- must be inserted into recess -A-.

-- Insert synchronizer ring -4-. Guide tabs -C- through recess -arrow-.

-- Install the 2nd gear wheel, the needle bearing and the synchronizer rings -A-. Place close attention to the position of the synchronizer rings INPUT SHAFT ASSEMBLY OVERVIEW .

Fig 9: Identifying 2nd Gear Wheel, Needle Bearing And Synchronizer Rings -A-

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NOTE:

The tabs -arrows- on the synchronizer rings must fit into the openings on the synchronizer hub when installing the 1st/2nd gear synchronizer hub.

Installing the 1st/2nd Gear Synchronizer Hub

Fig 10: Installing 1St/2Nd Gear Synchronizer Hub

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Heat the synchronizer hub to approximately 100 °C (212° F).
Synchronizer hub installed position: the higher inside collar is facing the 2nd gear wheel.

NOTE:

Slightly lift the 2nd gear wheel so that the tabs on the synchronizer ring can lock into the openings in the synchronizer hub.

-- Install the 1st/2nd gear synchronizer hub locking ring.

When replacing the synchronizer hub or the output shaft:

Determine the locking ring -1- for the 1st/2nd gear synchronizer hub.

Fig 11: Determining Locking Ring -1- For 1St/2Nd Gear Synchronizer Hub

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-- Determine thickest circlip which can still just be installed and insert it. For the part number.

The following locking rings are available:

Locking Ring Thickness (mm)
2.44	2.47	2.50

-- Install the 1st gear wheel, the synchronizer rings and the needle bearings on the output shaft.

-- Install the thrust washer -A- and then install the heated inner race -B- for the reverse gear needle bearing.

Fig 12: Installing Thrust Washer -A- And Then Install Heated Inner Race -B- For Reverse Gear Needle Bearing

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-- Install the reverse gear needle bearing, the gear wheel and the reverse gear locking collar INSTALLED POSITION: LOCKING COLLAR -2- AND REVERSE GEAR WHEEL -1- .

-- Install the reverse gear synchronizer ring in the locking collar.

-- Heat the reverse gear synchronizer hub to approximately 100 °C (212° F).