Output Shaft, 5TH, 6TH And Reverse Gears

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
• Transmission Support VW 353
• Thrust Pad Con. 8/65 VW 433
• Thrust Tube VW 454
• Support Channels VW 457
• Holding Fixture VW 801
• Thrust Pad 16.5/28 mm Dia. VW 431
• Thrust Tube VW 455
• Thrust Pad VW 510
• Tube 42 mm Dia. VW 516
• Sleeve VW 519
• Thrust Pad 30-11
• Thrust Piece 40-105
• Sleeve 40-20
• Thrust Plate 2050
• Tube 3296
• Tapered Roller Bearing Puller V.A.G 1582
• Attachment to VAG 1582 V.A.G 1582/4
• Grip V.A.G 1582/7
• Kukko Extractor 46-58 mm 21/7
• Kukko Separating Tool 22-115 mm 17/2
• Kukko Support 22/2

Fig 1: Exploded View Of Output Shaft For 5th, 6th And Reverse Gear Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Clutch Housing 
2. Washer 
   • Always 0.65 mm thick.
3. Outer Race/Tapered Roller Bearing 
   • Removing, refer to Fig 2.
   • Installing, refer to Fig 3.
4. Inner Race/Tapered Roller Bearing 
   • Removing, refer to Fig 10.
   • Installing, refer to Fig 20.
5. Output Shaft 
   • For the 5th, 6th and reverse gears.
   • Adjusting, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
6. Reverse Gear Synchronizer Hub 
   • Removing, refer to Fig 9.
   • Installed position, refer to Fig 11.
   • Installing, refer to Fig 12.
7. Locking Ring 
8. Reverse Gear Locking Collar 
   • With the synchronizer ring.
9. Needle Bearing 
   • For the reverse gear.
10. Reverse Gear 
11. Needle Sleeve 
    • Remove with the reverse gear, refer to Fig 8.
    • Installed position: the wider collar on the sleeve points toward the reverse gear selector gear.
    • Installing, refer to Fig 13.
12. Locking Ring 
13. Needle Bearing 
    • For the 6th gear.
14. 6th Gear 
15. Synchronizer Ring for 6th Gear 
    • Checking for wear, refer to Fig 14.
16. Locking Collar with Synchronizer Hub for 5th and 6th Gears 
    • After removing the locking ring, remove the 6th gear, refer to "Locking Ring" in item  17 and see Fig 7.
    • Disassembling, refer to Fig 15.
    • Assembling the locking collar/synchronizer hub, refer to Fig 15 and to Fig 16.
    • Installing, refer to Fig 17.
17. Locking Ring 
18. Needle Bearing 
    • For the 5th gear.
19. 5th Gear Synchronizer Ring 
    • Checking for wear, refer to Fig 14.
20. 5th Gear 
21. Inner Race/Tapered Roller Bearing 
    • Removing, refer to Fig 6.
    • Installing, refer to Fig 18.
22. Locking Ring 
    • Select the correct one when replacing the tapered roller bearing and the output shaft. Refer to "Inner Race/Tapered Roller Bearing" in item  21 and "Output Shaft" in item  5 and see Fig 19.
23. Outer Race/Tapered Roller Bearing 
    • Removing, refer to Fig 4.
    • Installing, refer to Fig 5.
24. Adjusting Shim 
    • To select the correct thickness, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
25. Transmission Housing 
26. Spring 
    • Installed position, refer to Fig 16.
27. Locking Sleeve 
28. Synchronizer Hub 
29. Locking Pieces 
    • Quantity: 3
    • Installed position, Refer to Fig 15.

Fig 2: Identifying Support/Puller/Extractor Assembly To Remove Tapered Roller Bearing Outer Race

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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 3: Identifying Tool Assembly To Install Outer Race/Tapered Roller Bearing Into Clutch Housing

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-- Place the washer under the outer race.

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

Fig 4: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

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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 5: Identifying Outer Race/Tapered Roller Bearing Pressed Into Transmission Housing

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

Disassembling the Output Shaft 

Fig 6: Identifying Tool Assembly To Remove Inner Race/Tapered Roller Bearing

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Before installing the tapered roller bearing puller:

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

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

Fig 7: Identifying Tools To Remove 5th And 5th Gear Synchro-Hub/Locking Collar With 5th Gear

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-- Remove the locking ring beforehand.

Fig 8: Identifying Tool Assembly To Remove Sleeve -A- Over Reverse Gear Wheel

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-- Remove the locking ring beforehand.

Fig 9: Identifying Tools To Remove Reverse Gear Synchro-Hub

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-- Remove the locking ring beforehand.

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

Fig 10: Identifying Tool Assembly To Remove Inner Race/Tapered Roller Bearing

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-- Mount the thrust pad 30-11 on the output shaft before removing the puller.

Assembling the Output Shaft 

Fig 11: Installation Position Of Reverse Gear Synchro-Hub

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The stop -arrow A- on the reverse gear locking collar faces the splines on the output shaft -arrow B-.

Fig 12: Identifying Tools To Press On Reverse Gear Synchro-Hub

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-- Install the locking ring.

-- Mount the reverse gear locking collar on the reverse gear synchronizer hub.

-- Install the reverse gear and the needle bearing.

Fig 13: Identifying Tools To Install Sleeve

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Installed position: wide collar points toward reverse gear selector gear.

-- Install the locking ring.

Fig 14: Identifying Check Of 4th Gear Synchro-Ring For Wear

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-- Press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- with a feeler gauge.

Fig 15: Exploded View Of Gear Locking Collar And Synchro-Hub Components

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1. Spring 
2. Locking piece 
3. Locking collar 
4. Synchronizer hub 

-- Slide the locking collar over the synchronizer hub.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Fig 16: Identifying 3rd And 4th Gear Locking Collar/Synchro-Hub

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The locking collar is pushed over the synchronizer hub.

-- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

-- Install the 6th gear with needle bearing.

-- Install the 6th gear synchronizer ring.

Fig 17: Identifying Tools To Install 5th And 5th Gear Locking Collar/Synchro-Hub

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On some locking collars, there is a chamfer on the outer diameter.

Installed position: the chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear

-- Turn the synchronizer ring so that the grooves line up with the locking pieces.

-- Install the locking ring.

-- Install the 5th gear synchronizer ring.

-- Install 5th gear selector gear with needle bearing.

Fig 18: Identifying Tools To Press On Inner Race/Tapered Roller Bearing

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-- Choose the correct locking ring and install, refer to Fig 19.

Fig 19: Identifying Circlip / Locking Ring Selection Method

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

-- Select the locking ring according to the table.

Available Locking Rings 

Fig 20: Identifying Tool Assembly To Install Inner Race/Tapered Roller Bearing

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