Assembling The Output Shaft: Notes
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| No. | Designation | Qty. | Fitting |
|---|---|---|---|
| -1- | Taper roller bearing | 1 | Heat to approx. 100 °C and press on using a suitable tubular piece (e.g. special tool 30-100 ). Press again after heat exchange. |
| -2- | Loose gear wheel, reverse gear | 1 | Insert spring before assembly. |
| -3- | Synchronizer ring | 1 | Check for wear. Fit with the same gear wheel (press off taper roller bearing - use the outer ring to do this). |
| -4- | Operating sleeve | 1 | Install operating sleeves in correct position. The slanted side is facing the loose gear wheel for reverse gear in the case of the operating sleeve for 5th and reverse gear. The slanted side is facing the loose gear wheel for 2nd gear in the case of the operating sleeve for 1st and 2nd gear. |
| -5- | Needle-roller bearing | 1 | Always fit with loose gear wheel for reverse gear. |
| -6- | Blue circlip | 1 | Calculate again if necessary. |
| -7- | Synchronizing hub | 1 | Heat to approx. 100 °C and press on. The high collar is facing the loose gear wheel for 5th gear. |
| -8- | Synchronizer ring, 5th gear | 1 | Check for wear. Fit with the same gear wheel (press off taper roller bearing - use the outer ring to do this). |
| -9- | Loose gear wheel, 5th gear | 1 | Insert spring before assembly. |
| -10- | Brown circlip | 1 | Must always be 2.00 mm thick. |
| -11- | Needle-roller bearing | 1 | Always fit with loose gear wheel for 5th gear. |
| -12- | Circlip | 1 | Calculate again if necessary. |
| -13- | Fixed gear wheel, 4th gear | 1 | Heat to approx. 100 °C and press on in the correct position so that the groove and high collar are facing 3rd gear. |
| -14- | Circlip | 1 | Calculate again if necessary. |
| -15- | Fixed gear wheel, 3rd gear | 1 | Heat to approx. 100 °C and press on in the correct position so that the groove is facing 4th gear. |
| -16- | Loose gear wheel, 2nd gear | 1 | Insert spring before assembly. |
| -17- | Friction ring, 2nd gear | 1 | Check for wear with synchronizer ring fitted. |
| -18- | Synchronizer ring, 2nd gear | 1 | Check for wear with friction ring fitted. Fit with gear wheel for 2nd gear. |
| -19- | Operating sleeve | 1 | Slant is facing 2nd gear. |
| -20- | Needle-roller bearing | 1 | Always fit with loose gear wheel for 2nd gear. |
| -21- | Blue circlip | 1 | Must always be 2.5 mm thick. |
| -22- | Blue circlip | 1 | Calculate again if necessary. |
| -23- | Synchronizing hub | 1 | Heat to approx. 100 °C and press on. The high collar is facing the loose gear wheel for 2nd gear. |
| -24- | Synchronizer ring, 1st gear | 1 | Check for wear with friction ring and cone ring fitted. |
| -25- | Cone ring, 1st gear | 1 | Check for wear with friction ring and cone ring fitted. |
| -26- | Friction ring, 1st gear | 1 | Check for wear with cone ring and synchronizer ring fitted. |
| -27- | Loose gear wheel, 1st gear | 1 | Insert spring before assembly. |
| -28- | Needle-roller bearing | 1 | Always fit with loose gear wheel for 1st gear. |
| -29- | Circlip | 1 | Always fit with loose gear wheel for 1st gear. |
| -30- | Taper roller bearing | 1 | Heat to approx. 100 °C and press on using a suitable tubular piece (e.g. special tool vw 415a ). Press again after heat exchange. |
| -31- | Output shaft | 1 | This is paired with the crown wheel (drive set). Readjust if replaced → 390815 ADJUSTING DRIVE SET . |
| -32- | Taper roller bearing outer ring | 1 | → DISASSEMBLING TRANSMISSION HOUSING |
| -33- | Adjusting shim S3 | X | → DISASSEMBLING TRANSMISSION HOUSING |
| -34- | Retaining sleeve | 1 | → DISASSEMBLING TRANSMISSION COVER |
| -35- | Taper roller bearing outer ring | 1 | → DISASSEMBLING TRANSMISSION COVER |
| -36- | Adjusting shim S4 | X | → DISASSEMBLING TRANSMISSION COVER |
| -37- | Pressure plate | 1 | → DISASSEMBLING TRANSMISSION COVER |
| -38- | Rubber washer | 1 | → DISASSEMBLING TRANSMISSION COVER |
| -39- | Transmission cover | 1 | → DISASSEMBLING TRANSMISSION COVER |
| -40- | Transmission housing | 1 | → DISASSEMBLING TRANSMISSION HOUSING |