Output Shaft For 5TH, 6TH And Reverse Gear, Disassembling And Assembling: Notes
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Fig 1: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (1 Of 6)
Special tools and equipment
- VW 401 Thrust plate
- VW 402 Thrust plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 412 Press tool
- VW 415 A Tube
Fig 2: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (2 Of 6)
Special tools and equipment
- VW 309 Holding plate
- VW 353 Transmission support
- VW 433 Press piece
- VW 454 Press piece
- VW 457 Support rail
- VW 801 Holding plate
Fig 3: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (3 Of 6)
Special tools and equipment
- VW 431 Press piece
- VW 455 Fitting sleeve
- VW 510 Press piece
- VW 516 Tube
- VW 519 Tube
- 30-11 Thrust plate
Fig 4: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (4 Of 6)
Special tools and equipment
- 40-105 Thrust plate
- 40-20 Press tool
- 2050 Thrust piece
- 3296 Tube
- VAG 1582 Tapered roller bearing puller
- VAG 1582/4 Grip
Special tools and equipment
Fig 5: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (5 Of 6)
- V.A.G 1582/7 Grip
Fig 6: Identifying Special Tools - Output Shaft For 5th, 6th And Reverse Gear, Disassembling And Assembling (6 Of 6)
- 1 - Kukko 21/7 Internal puller
- 3 - Kukko 17/2 Separating device
- 4 - Kukko 22/2 Counter support
NOTE:
- When installing new gears or a new output shaft consult technical data. Refer to Code letters, application, ratios, capacities .
- If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment. Refer to Output shaft for 5th, 6th and reverse gear, adjusting .
1 - Clutch housing
2 - Shim
- Always 0.65 mm thick
3 - Outer race/tapered roller bearing
4 - Tapered roller bearing inner race
5 - Output shaft
- For 5th, 6th and reverse gear
- Adjusting. Refer to Output shaft for 5th, 6th and reverse gear, adjusting
6 - Reverse gear synchro-hub
7 - Securing clip
8 - Reverse gear locking collar
- Securing clip
9 - Needle roller bearing
- For reverse gear
10 - Reverse sliding gear
11 - Sleeve
- Press off with reverse gear. See Figure
- Installed position: wide shoulder of sleeve faces reverse gear
- Pressing on. See Figure
12 - Securing clip
13 - Needle roller bearing
- For 6th gear
- Not in 5-speed manual transmissions
14 - 6th gear
- Not in 5-speed manual transmissions
15 - 6th gear synchro-ring
- Not in 5-speed manual transmissions
- Checking for wear. See Figure
16 - Spacer sleeve
- For 5-speed manual transmission
- Pull off together with 5th gear locking collar/synchro-hub after removing securing clip (item Output shaft for 5th, 6th and reverse gear, disassembling and assembling ). See Figure
- Position toward 5th gear locking collar/synchro-hub. See Figure
- Press on together with 5th gear locking collar/synchro-hub. See Figure
17 - 5th and 6th gear locking collar with synchro-hub
- After removing securing clip, press off together with 6th gear (item Output shaft for 5th, 6th and reverse gear, disassembling and assembling ). See Figure or for 5-speed manual transmission, with spacer sleeve. See Figure
- Disassembling. See Figure
- Assembling locking collar/synchro hub. See Figure and Figure
- Pressing off in 6-speed manual transmission. See Figure
- Pressing off in 5-speed manual transmission. See Figure
18 - Securing clip
19 - Needle roller bearing
- For 5th gear
20 - 5th gear synchro-ring
- Check for wear. See Figure
21 - Selector gear for 5th gear
22 - Tapered roller bearing inner race
23 - Securing clip
- Redetermine if tapered roller bearing (item Output shaft for 5th, 6th and reverse gear, disassembling and assembling ) or output shaft (item Output shaft for 5th, 6th and reverse gear, disassembling and assembling ) are replaced. See Figure
24 - Outer race/tapered roller bearing
25 - Shim
- Determining thickness. Refer to Output shaft for 5th, 6th and reverse gear, adjusting
26 - Transmission housing
27 - Spring
- Installed position. See Figure
28 - Locking collar
29 - Synchro-hub
30 - Locking pieces (Qty. 3)
- Installed position. See Figure