Bearing Bracket, Disassembling And Assembling: Assembling

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-- Warm the bearing bracket -3- in the area of the bearing seat -A arrows- using the Hot Air Blower.

-- Insert the output shaft ball bearing -1- and input shaft ball bearing -2- in the bearing bracket.

• Pay attention to the installation position of the ball bearing (grooves -B arrows-).

-- Secure the retaining plate -2- with the bolts -3- on the bearing bracket.

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-- Install the locking ring -1-.

• Locking ring installed position -1- : the flat side faces the ball bearing and the bevel -arrow- to the 1st gear assembly  .

-- Insert the reverse gear intermediate sprocket -1-, needle bearing -2- and the thrust washers -3- in the bearing bracket.

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• When installing the shaft for the reverse gear intermediate sprocket -1- place a feeler gauge -A- with the dimension 0.20 mm between the bearing bracket -2- and the thrust washer -3-.

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-- Push in the intermediate sprocket reverse gear shaft -1- with Sleeve:VW421  -B- all the way.

-- Then insert the circlip  OVERVIEW - BEARING BRACKET.

Locking sleeves, removing and installing

Fig 1: Retaining Sleeves, Removing and Installing

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The dimension -a- of the locking sleeve is determined by the Thrust Pieces:T40413/5  and :T40413/6  .

1. Locking Sleeve for 1st and 3rd Gear Gearshift Rail/Shift Fork
2. Locking Sleeve for 2nd and Reverse Gear Gearshift Rail/Shift Fork
3. Locking Sleeve for 4th and 6th Gear Gearshift Rail/Shift Fork
4. Locking Sleeve for 5th and 7th Gear Gearshift Rail/Shift Fork

Press on the locking sleeve 1

Fig 2: Press on the Locking Sleeve -1-

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2 -  Two-Arm Puller:VAS 251 001 

3 -  Puller - Transmission Gears - Thrust Piece:T10309/5 

Press in the locking sleeves A, B, C, D

Fig 3: Press in the New Retaining Sleeves -A, B, C and D-

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-- Press in the locking sleeve -A- for the gearshift rail / shift fork of the 1st and 3rd gear with the Thrust Piece:T40413/6  -2-.

-- Press in the locking sleeve -B- for the 2nd gear and reverse gear gearshift rail / shift fork, locking sleeve -C- for the gearshift rail / shift fork of the 4th gear and the 6th gear and the locking sleeve -D- for the gearshift rail / shift fork of the 5th gear and the 7th gear with Thrust Piece:T40413/5  -2-.

1 -  Extracting Tool - Spindle:T40413/4 

2 -  Thrust Piece for each Locking Sleeve

3 -  Extracting Tool - Bracket:T40413/3 

• Only press in the locking sleeves -A- and -B- after assembly of the gear set!