Input Shaft

Special tools and workshop equipment required 

• Punch VW 407
• Thrust Pad VW 447 h
• Thrust Disc VW 412
• Tube Split VW 422
• Thrust Plate VW 401
• Punch VW 408 A
• Thrust Plate VW 402
• Tube 28 mm Dia. 100 mm VW 421
• Thrust Pad VW 447 i
• Thrust Tube VW 454
• Thrust Pad VW 510
• Mounting Universal Joint 41-501
• Kukko Separating Tool 12-75 mm 17/1

Fig 1: Pressing Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 2: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing the Bearing Inner Race/Tapered Roller Bearing

Fig 3: Pressing Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Separating tool, for example, Kukko separating tool 12-75 mm17/1

Installing the Bearing Inner Race/Tapered Roller Bearing

Fig 4: Pressing On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing the 4th Gear with the Tapered Roller Bearing and Sleeve

Fig 5: Pressing Off 4th Gear With Tapered Roller Bearing And Sleeve Using Special Tools VW407, VW421 & VW401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing the 3rd Gear

Fig 6: Pressing Off 3rd Gear Using Special Tools VW408A, VW447H & VW401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 3rd Gear

Fig 7: Pressing On 3rd Gear Using Special Tools VW408A, VW447H & VW401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 4th Gear

The shoulder faces 3rd gear.

Fig 8: Pressing On 4th Gear Using Special Tools VW 412, VW 454 & VW 401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing the Bearing Inner Race/Tapered Roller Bearing

Fig 9: Pressing On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing the Needle Bearing Sleeve

Fig 10: Pressing On Sleeve For Needle Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing the Outer Race/Tapered Roller Bearing

Fig 11: Pressing Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing the Outer Race/Tapered Roller Bearing

-- Install with the shim after adjusting the input shaft.

Fig 12: Pressing In Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

5th Gear Synchronizer 

Fig 13: Identifying Springs For Lock Pieces, Locking Collar With Recesses, Synchro-Hub & Locking Pieces With Thin Extension

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1. Springs for the locking pieces
2. Locking collar with 3 notches -arrow A- for the locking pieces -4-
3. Synchronizer hub
4. Locking pieces - installed position: the extension -arrow B- faces toward the pointed teeth of the locking collar -item 2-

Fig 14: Assembling 5Th Gear Locking Collar/Synchronizer Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the locking collar over the synchronizer hub.

The pointed teeth -A- and the shoulder -B- on the synchronizer hub face in the same direction. Recesses for the locking pieces in the locking collar and synchronizer hub must line up (refer to Fig 13)

-- Insert locking pieces (Location: refer to Fig 13)

-- Install the springs offset by 120° under the tabs -C-. The angled end of the spring must be positioned in front of the locking pieces -arrows-.

Fig 15: Identifying Offset Springs -A- For 5th Gear Synchronization

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

These springs are installed on both sides.

-- Springs are only installed in conjunction with hollow locking pieces.

-- Insert locking pieces (Location: refer to Fig 13)

Spring Installed Position:

Fig 16: Installation Position Of (Offset) Spring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the springs 120° offset.

-- Angled end -A- of the spring must engage into the hollow locking piece.

It must be located below the tab -B- of the locking pieces.

The offset end always faces away from the synchronizer hub in the -direction of the arrow-.