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Drive Pinion Shaft: Reassembly

  1. Inspect all parts for wear or damage and replace as necessary. Press 1st and 2nd gear synchro rings onto gears and check clearance. See Figure .
  2. Specified clearance for new parts is .039-.067" (1.0-1.7 mm), with a minimum clearance of .020" (.5 mm) for used parts.
    NOTE: The 1st-2nd gear synchro ring (2nd-3rd on 5-speed), can be identified by having one groove in blank area on outer edge. Synchro for 3rd-4th gears (4th-5th on 5-speed), have 2 grooves in blank area on outer edge of ring.
  3. If synchro assembly was disassembled, install synchro assembly so that side with groove on sleeve is toward 2nd gear (3rd gear on 5-speed), and collar of synchro hub faces toward 1st gear (2nd gear on 5-speed).
  4. Heat tapered roller bearing to about 212°F (100°C) and press into position. Allow to cool to room temperature.
  5. Heat needle bearing inner race to about 140°F (60°C) and press on shaft by hand as far as possible. Place pinion in Holding Fixture (2052). Tighten inner race to 152 ft. lbs. (210 N.m).
  6. Check pinion bearing preload by installing shaft in transaxle case and tightening retaining ring. Rotate shaft in both directions 15-20 times. Check for turning torque of up to 180 INCH lbs. (20 N.m) for new bearing and up to 61 INCH lbs. (7 N.m) for used bearing.
  7. On 4-speed, install needle bearing and 1st gear. Install 1st-2nd synchro assembly, ensure synchro ring grooves align with keys when installing. Install circlip. Assemble needle bearing, 2nd gear and 3rd gear on shaft. Fit circlip properly in groove.
  8. On 5-speed, install needle bearing, 2nd gear, 2nd-3rd synchro assembly, ensure synchro ring grooves align with keys when installing. Assemble needle bearing, 3rd gear and 4th gear on shaft, then fit circlip properly in groove.
  9. On all models, check axial play between circlip and 3rd gear (4th gear on 5-speed). Correct play is .002-.007" (.05-.20 mm), with the lower limit preferred. Install proper circlip to obtain specified clearance. Refer to CIRCLIP THICKNESS  for proper circlip selection. Press on 4th gear (5th gear on 5-speed) and install circlip.
CIRCLIP THICKNESS

Identification Color Thickness mm
Black 1.60
Blue 1.75
Brown 1.90
Gray 2.05
Copper 2.20
Brass 2.30
Silver 2.40
Fig 1: Checking Pinion Bearing Preload
G95B55781Courtesy of VOLKSWAGEN UNITED STATES, INC.
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