Output Shaft: Notes
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Special tools and workshop equipment required
- PunchVW 407
- Thrust DiscVW 412
- Thrust PadVW 512
- Taper Roller Bearing PullerV.A.G 1582
- Attachment to VAG 1582V.A.G 1582/4
- Attachment to VAG 1582V.A.G 1582/5
- Thrust PlateVW 402
- Driving Sleeve32 - 111
- PunchVW 408 A
- PunchVW 409
- Support ChannelsVW 457
- SleeveVW 519
- Thrust RingVW 429
- Tube 60 mm Dia.VW 415 A
- Thrust PadVW 447 H
- Thrust TubeVW 454
- Thrust TubeVW 455
- Mounting Universal Joint41-501
- Kukko Extractor 37-46 mm21/6
- Kukko Separating Tool 22-115 mm17/2
- Kukko Support22/2
- Inductive HeaterVAS 6414
NOTE:
Disassemble the output shaft as follows: place the separating device under the 2nd gear -item 21- and remove it as described. Refer to Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft . Remove the lock ring -item 17-. Remove the locking collar and the 1st/2nd gear synchronizer hub as described in. Refer to Removing the Locking Collar with the Synchronizer Hub and Bearing Mount .
Replace both tapered roller bearings together.
Wearing safety gloves, warm the bearing inner races, the gears and the synchronizer hubs to approximately 100 °C (212 °F) using the VAS 6414 before installing them.
- Nut
- 25 Nm + 90° (1/4) additional turn.
- 4 nuts for the bearing mount.
- Always replace.
- Clutch Housing
- Adjusting Shim
- For the output shaft.
- Adjustment overview, refer to ADJUSTMENT OVERVIEW .
- Small Outer Race/Tapered Roller Bearing
- Removing, refer to Removing the Small Outer Race/Tapered Roller Bearing .
- Installing, refer to Installing the Small Outer Race/Tapered Roller Bearing .
- Bearing Inner Race/Small Tapered Roller Bearing
- Removing, refer to Removing the Bearing Inner Race/Small Taper Roller Bearing .
- Installing, refer to Installing the Bearing Inner Race/Small Tapered Roller Bearing .
- Output Shaft
- Adjusting, refer to OUTPUT SHAFT, ADJUSTING .
- Bearing Inner Race/Large Tapered Roller Bearing
- Removing, refer to Removing the Bearing Inner Race/Large Tapered Roller Bearing .
- Installing, refer to Installing the Bearing Inner Race/Large Tapered Roller Bearing .
- Seal
- Place the four seals on the bearing mount bolts.
- Always replace.
- Bearing Mount
- With the large outer race/tapered roller bearing and bolts.
- Replace the outer race only together with the large tapered roller bearing and bearing mount.
- Thrust Washer
- The collar on the thrust washer faces the tapered roller bearing.
- 1st Gear
- Needle Bearing
- For the 1st gear.
- Synchronizer Ring
- (Inner race for 1st gear).
- Installed position, refer to Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring
- Checking for wear, refer to Checking the Inner Race for 1st Gear and 2nd Gear for Wear .
- Check for scoring.
- 1st Gear Outer Race
- Installed position, refer to Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring .
- Checking for wear, refer to Checking 1st Gear and 2nd Gear synchronizing Ring for Wear .
- Replace if there are grooves or scoring.
- 1st Gear Synchronizer Ring
- Installed position, refer to Installed Position of the Inner Race, the Outer Race and the 1st Gear Synchronizer Ring .
- Checking for wear, refer to Checking 1st Gear and 2nd Gear synchronizing Ring for Wear .
- Locking Collar with Synchronizer Hub for 1st and 2nd Gears
- After removing the locking ring -item 17-, remove with the bearing mount. Refer to Removing the Locking Collar with the Synchronizer Hub and Bearing Mount
- Disassembling, refer to Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears .
- Assembling operating sleeve/synchronizer hub, refer to Disassembling and Assembling Locking Collar and Synchronizer Hub for 1st and 2nd Gears , Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are Hollow on the Inside and Assembly: Locking Collar/Synchronizer Hub for 1st and 2nd Gears together with Locking Pieces that are not Hollow .
- Installed position, refer to Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears .
- Installing, refer to Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears .
- Lock Ring
- 2nd Gear Synchronizer Ring
- Checking for wear, refer to Checking 1st Gear and 2nd Gear synchronizing Ring for Wear .
- Insert it so that the holes engage into engagement pieces of locking collar -item 16-.
- 2nd Gear Outer Race
- Insert into synchronizer ring -item 18-.
- Installed position, refer to Installed Position of 2nd Gear Outer Race .
- Replace if there are grooves or scoring.
- Synchronizer Ring
- (Inner race for 2nd gear).
- Checking for wear, refer to Checking 1st Gear and 2nd Gear synchronizing Ring for Wear .
- Check for scoring.
- Installed position, refer to Installed Position: Synchronizer Ring -A- (2nd Gear Inner Race) .
- 2nd Gear
- Installed position, refer to Installed Position: 2nd Gear .
- Needle Bearing
- For the 2nd gear.
- Thrust Washer
- Sleeve for the 3rd Gear Needle Bearing
- Remove with the 2nd gear, refer to Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft .
- Installing, refer to Installing the Sleeve for the 3rd Gear Needle Bearing .
- Needle Bearing
- For the 3rd gear.
- 3rd Gear
- 3rd Gear Synchronizer Ring
- Checking for wear, refer to Checking 3rd/4th Gear Synchronizing Ring for Wear .
- Locking Collar with Synchronizer Hub for 3rd and 4th Hears
- Remove with the 2nd gear -item 21- and 3rd gear -item 26-. Refer to Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft .
- Disassembling, refer to Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears .
- Assembling operating sleeve/synchronizer hub Disassembling and Assembling Locking Collar and Synchronizer Hub for 3rd/4th Gears , Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are Hollow on the Inside and Assembly: Locking Collar/Synchronizer Hub for 3rd and 4th Gears together with Locking Pieces that are not Hollow .
- Installed position: locking collar/synchronizer hub, refer to Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears
- Installing, refer to Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears .
- Sleeve
- For the 4th gear needle bearing.
- Removing with the locking collar and the 3rd/4th gear synchronizer hub -item 28-. Refer to Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft .
- Installing, refer to Installing the Sleeve for the 4th Gear Needle Bearing .
- Needle Bearing
- For the 4th gear.
- 4th Gear Synchronizer Ring
- Checking for wear, refer to Checking 3rd/4th Gear Synchronizing Ring for Wear .
- 4th Gear
- Thrust Washer
- Needle Bearing
- For the output shaft.
- Removing and installing, see -item 2- TRANSMISSION HOUSING AND CLUTCH HOUSING => Needle Bearing .
- Transmission Housing
- Sleeve
- For the needle bearing/output shaft.
- Removing, refer to Removing the Synchronizer and 3rd/4th Gear Locking Collar, 2nd, 3rd and 4th Gears with the Needle Bearing Sleeve and Output Shaft .
- Installing, refer to Installing the Sleeve for the Needle Bearing/Output Shaft .
- 5th Gear
- Removing individually, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .
- Remove with the transmission housing. Refer to TRANSMISSION .
- Plate Spring
- Installed position, refer to 5TH GEAR, INSTALLING => Installed Position of Plate Springs for 5th Gear Synchronizer Hub and Drive Gear Bolts .
- Bolt
- See -item 4- TRANSMISSION HOUSING AND 5TH GEAR COVER => Bolt .
- Always replace
- Removing and installing TRANSMISSION .