Output shaft for 1st to 4th gear, disassembling and assembling: Notes
WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.
Special tools, testers and auxiliary items required
Fig 1: Identifying Special Tools -- Output Shaft, 1st-4th Gear, Disassembling And Assembling (1 Of 4)
- Pressure plate VW 401
- Pressure plate VW 402
- Punch VW 407
- Punch VW 408 A
- Punch VW 412
- Tube VW 415 A
Special tools, testers and auxiliary items required
Fig 2: Identifying Special Tools -- Output Shaft, 1st-4th Gear, Disassembling And Assembling (2 Of 4)
- Holding plate VW 309
- Holding fixture VW 313
- Engine support adapter VW 353
- Thrust piece VW 431
- Thrust piece VW 433
- Thrust piece VW 454
Special tools, testers and auxiliary items required
Fig 3: Identifying Special Tools -- Output Shaft, 1st-4th Gear, Disassembling And Assembling (3 Of 4)
- Thrust pad VW 512
- Tube VW 516
- Tube VW 519
- Slide hammer VW 771
- Holding plate VW 801
- Thrust piece 40-105
Special tools, testers and auxiliary items required
Fig 4: Identifying Special Tools -- Output Shaft, 1st-4th Gear, Disassembling And Assembling (4 Of 4)
- Seal driver-frt wheel bearing 40-20
- Seal driver-frt wheel bearing 40-21
- Thrust piece 2050
- Extension 3161
- Tapered roller bearing puller V.A.G 1582
- Attachment V.A.G 1582/7
Special tools, testers and auxiliary items required
- Internal puller 1- Kukko 21/7
- Internal puller 1- Kukko 21/8
- Extractor 2- Kukko 18/2
- Separating device 3- Kukko 17/2
- Support 4- Kukko 22/2
NOTE:
- If output shaft or tapered roller bearings are replaced, output shaft must be adjusted. → Output shaft for 1st to 4th gear, adjusting .
- Replace both tapered roller bearings together.
1 - Clutch housing
2 - Oil deflector ring
3 - Dished washer
- Pulling out: Pulling dished washer - A - off output shaft
- Pressing in: Pressing dished washer in output shaft to stop
4 - Tapered roller bearing outer race
- Pulling out: Pulling out tapered roller bearing outer race
- Pressing in: Pressing outer race/tapered roller bearing into clutch housing
5 - Inner race/tapered roller bearing
- Pressing off: Pulling off inner race/tapered roller bearing
- Pressing on: Pressing on inner race/tapered roller bearing
6 - Output shaft
- For 1st to 4th gear
- Adjusting → Output shaft for 1st to 4th gear, adjusting
7 - Needle bearing
- For 2nd gear
8 - Gear wheel for 2nd gear
9 - Synchronizer ring
- (Inner race for 2nd gear)
- Checking for wear: Checking 1st, 2nd and 3rd gear inner races for wear
- Checking tabs for signs of wear
- Installed position: Installed position of outer race, inner race and synchronizer ring, 2nd gear
10 - Outer race for 2nd gear
- Replace if scored or showing signs of wear
- Installed position: Installed position of outer race, inner race and synchronizer ring, 2nd gear
11 - Synchronizer ring for 2nd gear
- Checking for wear: Checking 1st, 2nd and 3rd gear synchronizer rings for wear
- Installed position: Installed position of outer race, inner race and synchronizer ring, 2nd gear
12 - Operating sleeve with synchronizer hub for 1st and 2nd gears
- Disassembling: Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Assembling operating sleeve/synchronizer hub: Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Installed position: Installed position of operating sleeve/synchronizers for 1st and 2nd gear
- Pressing on: Pressing on operating sleeve/synchronizer hub for 1st and 2nd gear
13 - Circlip
14 - Synchronizer ring for 1st gear
- Checking for wear: Checking 1st, 2nd and 3rd gear synchronizer rings for wear
15 - Outer race for 1st gear
- Replace if scored or showing signs of wear
16 - Synchronizer ring
- (Inner race for 1st gear)
- Checking for wear: Checking 1st, 2nd and 3rd gear inner races for wear
- Checking tabs for signs of wear
- Installed position: Installed position of synchronizer ring - A - (inner race for 1st and 3rd gear)
17 - Needle bearing
- For 1st gear
18 - Gear wheel for 1st gear
- Installed position: Installed position of gear wheel for 1st and 3rd gear
19 - Thrust plates
- For 1st and 4th gear
- Insert tabs of thrust washer in output shaft hole
20 - Washer
21 - Needle bearing
- For 4th gear
22 - Gear wheel for 4th gear
23 - Synchronizer ring for 4th gear
- Checking for wear: Checking 4th gear synchronizer ring for wear
24 - Operating sleeve with synchronizer hub for 3rd and 4th gears
- Disassembling: Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Installed position of operating sleeve/synchronizer hub: Installed position of operating sleeve/synchronizers for 3rd and 4th gear
- Assembling operating sleeve/synchronizer hub: Disassembling and assembling operating sleeve and synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears and Assembling operating sleeve/synchronizer hub for 1st and 2nd gears as well as 3rd and 4th gears
- Pressing on: Pressing on synchronizer hub with operating sleeve for 3rd and 4th gears
25 - Circlip
26 - Synchronizer ring for 3rd gear
- Checking for wear: Checking 1st, 2nd and 3rd gear synchronizer rings for wear
27 - Outer race for 3rd gear
- Replace if scored or showing signs of wear
28 - Synchronizer ring
- (Inner race for 3rd gear)
- Checking for wear: Checking 1st, 2nd and 3rd gear inner races for wear
- Checking tabs for signs of wear
- Installed position: Installed position of synchronizer ring - A - (inner race for 1st and 3rd gear)
29 - Needle bearing
- For 3rd gear
30 - Gear wheel for 3rd gear
- Installed position: Installed position of gear wheel for 1st and 3rd gear
31 - Inner race/tapered roller bearing
- Pulling off: Pulling off inner race/tapered roller bearing
- Pressing on: Pressing on inner race/tapered roller bearing
32 - Circlip
33 - Tapered roller bearing outer race
- Pulling out: Pulling outer race/tapered roller bearing out of transmission housing
- Pressing in: Pressing outer race/tapered roller bearing into transmission housing
34 - Adjustment shim
- Determining thickness → Output shaft for 1st to 4th gear, adjusting
35 - Transmission housing