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 408A
- Thrust Disc VW 412
- Tube 60 mm dia. VW 415A
- 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 V.A.G 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
Disassembly
Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing
-- Install the thrust pad -30-11- on the output shaft before installing the puller.
Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing.
Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing.
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
Check the washer for damage after removing it and replace if necessary.
Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing
-- Place the washer under the outer race.
-- 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
Before installing the tapered roller bearing puller:
-- Remove the inner race/tapered roller bearing locking ring on the side facing the transmission housing.
-- Install the thrust pad 16.5/28 mm dia. -VW 431- and thrust piece -40-105- on the output shaft.
Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing
-- Choose the correct locking ring, refer to Fig 7 and install.
Selecting the Locking Ring
-- Choose and install the thickest locking ring that will fit.
Available Locking Rings
| Thickness (mm) | ||
|---|---|---|
| 1.79 | 1.89 | 1.98 |
| 1.83 | 1.92 | |
| 1.86 | 1.95 | |
Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing
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
-- Support the transmission housing under the bearing mount using the thrust plate 2050.
Disassembling the Output Shaft
Remove the inner race/tapered roller bearing on the side of the transmission housing. Refer to Fig 5.
Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar and 6th Gear
-- Remove the locking ring beforehand.
Removing the Sleeve -A- over Reverse Gear
-- Remove the locking ring beforehand.
Removing the Reverse Gear Synchronizer Hub
-- Remove the locking ring beforehand.
A - Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm 17/2
Assemble the Output Shaft
Installed Position: Reverse Gear Synchronizer Hub
The stop -arrow A- on the reverse gear locking collar faces the splines on the output shaft -arrow B-.
Installing the Reverse Gear Synchronizer Hub
-- Install the locking ring.
-- Mount the reverse gear locking collar on the reverse gear synchronizer hub.
-- Install the reverse gear wheel and the needle bearing.
Installing the Sleeve -A
Installed position: wide collar points toward reverse gear selector gear.
-- Install the locking ring.
Checking 5th and 6th Gear Synchronizer Ring for Wear
-- Press synchronizer ring onto taper of the gear wheel and measure gap dimension -a- using a feeler gauge.
| Gap dimension -a- | Installed dimension | Wear limit |
|---|---|---|
| 5. and 6th gear | 1.0 to 1.7 mm | 0.5 mm |
Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears
- Spring
- Locking piece
- Locking collar
- 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.
Assembling the Locking Collar/Synchronizer Hub for 5th and 6th Gears
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.
Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears
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.