Output Shaft, Disassembling And Assembling

Special tools and workshop equipment required

Bearing Installer - Differential Bearing: 40-21
Press Piece - Trailing Arm: 2010
Inductive Heater: VAS6414
Press Plate: VW402
Press Piece - Multiple Use: VW412
Press Piece - Multiple Use: VW519
Press Piece - 37mm: VW416B
Press Piece - 60mm: VW415A
Press Piece - Multiple Use: VW429
Press Piece - Bushing: 3118

Disassembling

Gear set disassembled. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .

CAUTION:

Risk of damaging the output shaft!

Secure the output shaft from felling when pressing on!

Press Out the Output Shaft 1, Vehicles without Self-Locking Center Differential

Fig 1: Press Out the Output Shaft -1-, Vehicles without Self-Locking Center Differential

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2 -

Press Plate: VW402

3 -

Press Piece - Multiple Use: VW412

CAUTION:

Damage to the output shaft components.

Individual components may fall out when removing.

Press Out the Output Shaft 1, Vehicles with Self-Locking Center Differential

Fig 2: Press Out the Output Shaft -1-, Vehicles with Self-Locking Center Differential

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2 -

Press Plate: VW402

3 -

Press Piece - Multiple Use: VW412

4 -

Press Piece - 37mm: VW416B

CAUTION:

Damage to the output shaft components.

Individual components may fall out when removing.

Continuation for All Vehicles

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The following components can now be removed:

6th Gear
Thrust Washer
2nd Gear Assembly
Needle Bearing
Inner Race/Needle Bearing

-- Switch the gearshift rail/shift fork for the 2nd and reverse gear -1- in the direction of -arrow A-.

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-- Remove the synchronization for the 2nd and reverse gear -2- with all individual parts put of the shift fork -1- in the direction of -arrow B-.

-- Turn the gearshift rail/shift fork for the 2nd and reverse gear -1- slightly to the side and remove it from the bearing bracket.

The following components can now be removed:

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Reverse Gear Assembly
Needle Bearing
Inner Race/Needle Bearing
Thrust Washer

-- Remove the bearing bracket with the shift fork -1- in direction of the -arrow- from the synchronization -3-.

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The following components can now be removed:

2 -

1st Gear Assembly with: Thrust Washer, Needle Bearing, Inner Race/Needle Bearing

3 -

Synchronization for 1st Gear Assembly / 3rd Gear Assembly with All Individual Parts

4 -

3rd gear assembly with the needle bearing

Assembling

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-- Position the needle bearing -1-, 3rd gear assembly -2- and synchronizer rings -3-.

Pay attention to the installation position of the synchronizer rings. Refer to Figure.

Synchronizer Hub for 1st Gear Assembly / 3rd Gear Assembly 2, Pressing On

Fig 3: Synchronizer Hub for 1st Gear Assembly / 3rd Gear Assembly -2-, Pressing On

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Warm the synchronizer hub -2- using the Inductive Heater: VAS6414 to 100 °C (212 °F).
The lettered side of the synchronizer hub points to the Press Piece - Lower Ball Joint: 3146 -3-.

1 -

Press Plate: VW402

3 -

Press Piece - Lower Ball Joint: 3146

4 -

Press Piece - Bushing: 3118

5 -

Press Piece - 60mm: VW415A

6 -

Press Piece - Trailing Arm: 2010 (Only on Vehicles with Self-Locking Center Differential)

7 -

Press Piece - Multiple Use: VW412

-- Lift the 3rd gear assembly -8- with 3rd gear assembly -9- slightly, until the anti-twist mechanism -arrow B- of the synchronization is flush with the cut-outs -arrow A- of the synchronizer hub -2-.

-- Insert the three thrust pieces -arrows-.

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-- Push the double-toothed locking collar onto the opening -arrow A- with the lettering facing upward.

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-- Press the tops of the thrust pieces in slightly by hand when installing.

Inner Race Needle Bearing 1 for 1st Gear Wheel, Installing

Fig 4: Inner Race Needle Bearing -1- for 1st Gear Wheel, Installing

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Layout of the oil filler hole -arrows- at an offset of approximately 90°.
Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Multiple Use: VW429 .

2 -

Press Piece - Multiple Use: VW429

3 -

Press Piece - 60mm: VW415A

4 -

Press Piece - Bushing: 3118

5 -

Press Piece - Multiple Use: VW519 (Only on Vehicles with Self-Locking Center Differential)

-- Position the synchronizer rings for 1st gear -1-, needle bearing for 1st gear assembly -2-, and 1st gear assembly -3- and the thrust washer -4-.

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Tip:

The illustration shows a similar gear assembly!
Pay attention to the installation position of the synchronizer rings -arrow-. Refer to Figure.

-- Press out the locking sleeves for the 1st and 3rd gear -1- and the 2nd and reverse gear -2- out of the bearing bracket. Refer to Figure.

Fig 5: Retaining Sleeves, Removing and Installing

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Bearing Bracket 3, Pressing on

Fig 6: Bearing Bracket -3-, Pressing on

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Insert the shift fork for 1st and 3rd gear -1- in the locking collar for 1st and 3rd gear -2-.
Then pressing on the gearshift rail for the 1st and 3rd gear -arrow- guide in the bearing bracket -3-.

4 -

Press Piece - 60mm: VW415A

5 -

Press Piece - Multiple Use: VW429

6 -

Press Piece - Multiple Use: VW519

Needle Bearing Inner Race 2 for the Reverse Gear Assembly

Fig 7: Needle Bearing Inner Race -2- for the Reverse Gear Assembly

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Position the thrust washer -1- beforehand.
Layout of the oil filler hole -arrows- at an offset of approximately 90°.
Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Multiple Use: VW519 .

3 -

Press Piece - Multiple Use: VW519

4 -

Press Piece - Multiple Use: VW429

5 -

Press Piece - 60mm: VW415A

-- Position the reverse gear assembly needle bearing -1- and reverse gear assembly -2- and synchronizer ring -3-.

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Synchronizer Hub for the 2nd Gear Assembly / Reverse Gear Assembly 1, Pressing On

Fig 8: Synchronizer Hub for the 2nd Gear Assembly / Reverse Gear Assembly -1-, Pressing On

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Warm the synchronizer hub -1- using the Inductive Heater: VAS6414 to 100 °C. (212 °F)
The lettered side of the synchronizer hub points to the Press Piece - Bushing: 3118 .

-- Lift the reverse gear synchronizer ring -6- with reverse gear assembly -5- slightly, until the anti-twist mechanism -arrow B- of the synchronization is flush with the cut-outs -arrow A- of the synchronizer hub -1-.

2 -

Press Piece - Bushing: 3118

3 -

Press Piece - Multiple Use: VW519

4 -

Bearing Installer - Differential Bearing: 40-21 (Only on vehicles without self-locking center differential)

-- Insert the three thrust pieces -arrows-.

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-- Insert the shift fork for the 2nd gear / reverse gear -1- in the locking collar for the 2nd gear / reverse gear -2-.

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-- Guide in the shift fork with the locking collar for the 2nd gear / reverse gear in the bearing bracket -arrow A-.

The bevel of the locking collar -arrow- points to the 2nd gear assembly

-- Press on the double-toothed locking collar on the cut-out -arrow A-.

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-- Press the tops of the thrust pieces in slightly by hand when installing.

Needle Bearing Inner Race 1, 2nd Gear Wheel, Installing

Fig 9: Needle Bearing Inner Race -1-, 2nd Gear Wheel, Installing

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Layout of the oil filler hole -arrows- at an offset of approximately 90°.
Installation position: the lettering on the bearing -2- (thicker wall thickness) points to the Press Piece - Multiple Use: VW519 .

2 -

Press Piece - Multiple Use: VW519

3 -

Bearing Installer - Differential Bearing: 40-21 (Only on vehicles without self-locking center differential)

-- Press on the synchronizer rings for 2nd gear -1-, needle bearing for 2nd gear assembly -2-, and 2nd gear assembly -3- and the thrust washer -4-.

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The illustration shows a similar gear assembly!
Pay attention to the installation position of the synchronizer rings -arrow-. Refer to Figure.

Installing the 6th Gear Wheel 1

Fig 10: Installing the 6th Gear Wheel -1-

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Warm the 6th gear using the Inductive Heater: VAS6414 to 120 °C (248 °F).

2 -

Press Piece - Multiple Use: VW519

3 -

Bearing Installer - Differential Bearing: 40-21 (Only on vehicles without self-locking center differential)

-- Assemble the gear set. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .