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

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Special tools and workshop equipment 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-.

Fig 1: Locating Bolts To Attach Special Tools

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-- Insert the adapter T40213/6 and T40213/7 into the plate T40213/1.

NOTE:

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.

Fig 2: Identifying Input & Output Shafts

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-- 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-.

Fig 3: Removing/Installing Thrust Washer And Gears

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-- Remove the 1st gear wheel -E- along with the inner race/needle bearing for reverse gear -C- and the thrust washer -D-.

Fig 4: Removing 1ST Gear Wheel

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

B - Extraction hook 200 mm

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 2nd gear wheel -E- along with the inner race/needle bearing for 1st gear -C- and the synchronizer hub/locking collar -D-.

Fig 5: Removing 2nd Gear Wheel

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

B - Extraction hook 200 mm

-- Remove the needle bearing -1-.

Fig 6: Removing Needle Bearing

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-- Remove the bearing bracket -2- from the input -4- and output shafts -3-.

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 Output Shaft

-- Install the plate T40213/1 with the adapters T40213/6 and T40213/7 on the V.A.G 1290A table.

Fig 7: Locating Raised Surfaces

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-- 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.

Fig 8: Installation Position Of Synchronizer Rings For 1ST And 2ND Gear

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NOTE:

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.

Fig 9: Installing Synchronizer Hub With Locking Collar For 1ST And 2ND Gears

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NOTE:

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

Note the locking collar/synchronizer hub installed location; refer to Figure.

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

Fig 10: Heat Inner Race/Needle Bearing -A- For 1ST Gear Wheel Up To Approximately 100 °C (212 °F) And Install

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

Fig 11: Installing 1st Gear Wheel

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-- 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.

Fig 12: Removing/Installing Thrust Washer And Gears

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-- Mount the reverse gear synchronizer hub -B- along with the synchronizer rings and thrust washer -A-.

-- Mount the plate T40213/1 on the T40206.

Fig 13: Identifying Input & Output Shafts

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-- 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.