Output Shaft, 1ST To 4TH Gears: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 407
Punch VW 408A
Thrust Disc VW 412
Tube 60 mm dia. VW 415A
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 Kukko 21/8
Kukko Puller 18/2
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/2

Disassembling

Removing the Dished Washer -A- from the Output Shaft

Fig 1: Pull Dished Washer Out Of Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing the Dished Washer onto the Output Shaft

Fig 2: Pressing Dished Washer Into Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-a- = 2 mm

Removing the Inner Race/Tapered Roller Bearing on the side of the Clutch Housing

Fig 3: Pressing Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing

Fig 4: Pressing On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing

Fig 5: Pulling Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing

Fig 6: Pressing Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing

Fig 7: Pulling Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before installing the tapered roller bearing puller:

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

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

Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing

Fig 8: Pressing On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Selecting the Locking Ring

Fig 9: Determining Circlip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

The following locking rings are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing

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

Courtesy of VOLKSWAGEN UNITED STATES, 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

Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing

Fig 11: Pressing Tapered Roller Bearing Outer Race Into Transmission Housing

Courtesy of VOLKSWAGEN UNITED STATES, 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.

Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear

Fig 12: Pulling Off 3rd And 4th Gear Synchro-Hub/Locking Collar Over 4th Gear Wheel

Courtesy of VOLKSWAGEN UNITED STATES, 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

-- Remove the thrust washers for 1st and 4th gears.

-- Remove the 1st gear selector gear.

Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear

Fig 13: Pressing Off 1st And 2nd Gear Locking Collar And Synchro-Hub

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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