Output Shaft, Disassembling And Assembling

Special tools and workshop equipment required 

• Press Plate :VW402 
• Press Piece - Multiple Use :VW429 
• Press Piece - Multiple Use :VW412 
• Press Piece - Bushing :3118 
• Inductive Heater :VAS 6414 
• Press Piece - Trailing Arm :2010 
• Press Piece - Lower Ball Joint :3146 
• Press Piece - 60mm :VW415A 
• Press Piece - Multiple Use :VW519 
• Bearing Installer - Differential Bearing :40-21 

-- Disassembling the gear set. Refer to Gear Set, Disassembling and Assembling  .

-- Press off the output shaft -1- with the Press Plate : VW402  -2- and Press Piece - Multiple Use : VW412  .

-- The following components can now be removed:

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1. 6th Gear
2. Thrust Washer
3. 2nd Gear Assembly
4. Needle Bearing
5. Inner Race/Needle Bearing

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

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

-- Turn the gearshift rail/fork for the 2nd gear 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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1. Reverse Gear Assembly
2. Needle Bearing
3. Inner Race/Needle Bearing
4. Thrust Washer

-- Remove the bearing bracket with the shift fork -1- in the -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 and Inner Race/Needle Bearing
• 3 -  Synchronization for 1st Gear Shift Fork / 3rd Gear Assembly with All Individual Parts
• 4 -  3rd Gear Assembly with Needle Bearing

Assembling

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

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-- Pay attention to the installation position of the synchronizer rings. Refer to OVERVIEW - OUTPUT SHAFT, SYNCHRONIZATION .

Synchronizer hub for 1st gear assembly / 3rd gear assembly, pressing on

-- Warm the synchronizer hub -2- using the Inductive Heater :VAS 6414  to 100 °C (212 °F).

-- Pay attention to the installation position of the synchronizer hub: the lettering side faces the Press Piece - Lower Ball Joint : 3146  -3-.

-- Press on the synchronizer hub for 1st gear assembly / 3rd gear assembly -2-.

• 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 
• 7 -  Press Piece - Multiple Use :VW412 

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

-- Insert 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 for 1st Gear Assembly, Installing 

-- Layout of the oil filler hole -arrows- at an offset of approximately 90°.

-- Pay attention to the installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Multiple Use :VW429  .

-- Press on the inner race needle bearing -1-.

• 2 -  Press Piece - Multiple Use :VW429 
• 3 -  Press Piece - 60mm :VW415A 
• 4 -  Press Piece - Bushing :3118 
• 5 -  Press Piece - Multiple Use :VW519 

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

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Conditions

• The illustration above shows a similar gear assembly!
• Pay attention to the installation position of the synchronizer rings -arrow-. Refer to OVERVIEW - OUTPUT SHAFT, SYNCHRONIZATION .

Press off the locking sleeves.

-- Press the locking sleeves for 1st and 3rd gear -1- and for 2nd and reverse gear -2- out of the bearing bracket. Refer to Bearing Bracket, Disassembling and Assembling  .

Bearing bracket, pressing on

-- Insert the shift fork for 1st and 3rd gear 1 in the locking collar for 1st and 3rd gear 2.

-- Then while 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 for the reverse gear assembly

-- Install the thrust washer 1.

-- Layout the oil filler holes arrows at an offset of approximately 90 °.

Conditions

• Installation position: the lettering on the bearing 2 (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, pressing on

-- Warm the synchronizer hub 1 using the Inductive Heater VAS 6414 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 synchronizer ring 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 

-- 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.

Conditions

• 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 for 2nd Gear Assembly, Installing 

-- Layout the oil filler holes arrows at an offset of approximately 90 °.

Conditions

• Installation position: the lettering on the bearing 1 (thicker wall thickness) points to the Press Piece - Multiple Use VW519.

• 2 -  Press Piece - Multiple Use :VW519 
• 3 -  Bearing Installer - Differential Bearing :40-21 

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

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Conditions

• The illustration above shows a similar gear assembly!
• Pay attention to the installation position of the synchronizer rings -arrow-. Refer to OVERVIEW - OUTPUT SHAFT, SYNCHRONIZATION .

6th Gear, Pressing on

-- Warm up the 6th gear with the Inductive Heater : VAS 6414  to 120 °C (248 °F).

-- Press on the 6th gear -1-.

• 2 -  Press Piece - Multiple Use :VW519 
• 3 -  Bearing Installer - Differential Bearing :40-21 

Gear Set, Assembling

-- Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .