Output Shaft, 1ST To 4TH Gears: Notes

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 407
Punch VW 408 A
Thrust Disc VW 412
Tube 60 mm Dia.VW 415 A
Holding Plate VW 309
Holding Fixture VW 313
Transmission Support VW 353
Thrust Pad 16.5/28 mm Dia.VW 431
Thrust Pad Con. 8/65 VW 433
Thrust Tube VW 454
Thrust Pad VW 512
Tube 42 mm Dia.VW 516
Sleeve VW 519
Slide Hammer-Complete Set VW 771
Holding Fixture VW 801
Thrust Piece 40-105
Sleeve 40-20
Sleeve 40-21
Thrust Plate 2050
Spacers VW 540/1 B
Tapered Roller Bearing Puller V.A.G 1582
Grip V.A.G 1582/7
Kukko Extractor 46-58 mm 21/7
Kukko Extractor 21/8
Kukko Puller 80-210 mm 18/2
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/2

Fig 1: Identifying Tools To Pull Dished Washer Out Of Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 2: Identifying Tool To Press Dished Washer Into Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-a- = 2 mm

Fig 3: Identifying Kukko Separating Tool Assembly To Press Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Separating tool 22 to 115 mm, for example, kukko separating tool 22-115 mm 17/2

Fig 4: Identifying Tool Assembly To Press On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 5: Identifying Kukko Tool Assembly To Pull Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter-support, for example, kukko support 22/2

B - Internal puller 56 to 70 mm, for example, kukko extractor 21/8

Fig 6: Identifying Tool Assembly To Press Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the clutch housing using the sleeve 40-20 directly under the bearing mount.

Fig 7: Identifying Tool Assembly To Pull Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before installing the tapered roller bearing puller:

-- Remove the inner race/tapered roller bearing locking ring on the side facing the clutch housing.

-- Mount the thrust pad 16.5/28 mm dia. VW 431 in the output shaft and lay the thrust piece 40-105.

Fig 8: Identifying Tool Assembly To Press On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Choose the correct locking ring and install, refer to Fig 9.

Fig 9: Identifying Circlip / Locking Ring Selection Method

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-- Choose and install the thickest locking ring that will fit.

NOTE: The following locking rings are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Fig 10: Identifying Tapered Roller Bearing Outer Race Pulled Out From Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter-support, for example, kukko support 22/2

B - Internal puller 46 to 58 mm, for example, kukko extractor 46-58 mm 21/7

Fig 11: Identifying Tapered Roller Bearing Outer Race Pressed Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the adjusting shim under the outer race.

-- Support the transmission housing under the bearing mount using the thrust plate 2050.

Disassembling the Output Shaft

NOTE:

Removing the inner race/tapered roller bearing on the side of the clutch housing. Refer to Fig 7.

Fig 12: Identifying Puller/Separator Assembly To Pull Off 3rd And 4th Gear Synchro-Hub/Locking Collar Over 4th Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the locking ring beforehand.

A - Puller, for example, kukko puller 80-210 mm 18/2

B - Separating tool 22 to 115 mm, for example, kukko separating tool 22-115 mm 17/2

Fig 13: Identifying Tool Assembly To Press Off 1st And 2nd Gear Locking Collar And Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

After removing the circlip, press off the selector gear for the 2nd gear and locking collar/synchronizer hub together.