Output Shaft

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Punch VW 407
Thrust Disc VW 412
Thrust Pad VW 512
Taper Roller Bearing Puller V.A.G 1582
Attachment to VAG 1582 V.A.G 1582/4
Attachment to VAG 1582 V.A.G 1582/5
Thrust Plate VW 402
Driving Sleeve 32-111
Punch VW 408 A
Punch VW 409
Support Channels VW 457
Sleeve VW 519
Thrust Ring VW 429
Tube 60 mm Dia. VW 415 A
Thrust Pad VW 447 h
Thrust Tube VW 454
Thrust Tube VW 455
Mounting Universal Joint 41-501
Kukko Extractor 37-46 mm 21/6
Kukko Support 22/2
Kukko Separating Tool 22-115 mm 17/2

Remove/Installing the Small Outer Race/Tapered Roller Bearing

Fig 1: Pulling Off Small Outer Race/Tapered Roller Bearing

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A -

Internal puller 37 to 46 mm, for example, Kukko extractor 37-46 mm21/6

B -

Counter support, for example, Kukko support22/2

Fig 2: Pressing In Small Outer Race/Tapered Roller Bearing

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Fig 3: Pulling Off Small Inner Race/Tapered Roller Bearing

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A -

Protective jaws/vise

-- Mount the grip and apply tension behind the bearing. Then rotate the bearing and apply tension to the grip.

Fig 4: Pressing On Small Tapered Roller Bearing Inner Race

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Fig 5: Pressing Off 3rd And 4th Gear Synchro-Hub/Locking Collar, 2nd, 3rd And 4th Gears With Transmission Housing Needle Roller Bearing Sleeve

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A -

Separating tool 22 to 115 mm, for example, Kukko separating tool 22-115 mm17/2

B -

17 mm, M10 x 20 bolt

NOTE:

Support the separating tool so that the 1st/2nd gear locking collar does not come off as well.

Fig 6: Pressing Off Locking Collar With Synchronizer Hub And Bearing Mount

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-- Remove the lock ring -arrow- first.

Fig 7: Pulling Off Large Inner Race/Tapered Roller Bearing

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A - Jaw protectors

-- Before installing the puller, insert a M10 x 20 bolt into the hole in the output shaft.

Fig 8: Pressing On Inner Race Of Large Taper Roller Bearing

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-A- thrust washer

-- Install the thrust washer before installing the inner race. The shoulder faces the inner race.

Fig 9: Exploded View Of Modified 1st Gear Synchronization Components (From Transmission Build Date 02 05 0)

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-- Place the inner race -A- on the drive gear for 1st gear.

The angled tabs -arrow 1- face the outer race -B-.

-- Install the outer race -B-.

The tabs -arrow 2- must lock into the retainers -arrow 3- in the gear.

-- Install the synchronizer ring -C-.

The retainers -arrow 4- lock in the tabs -arrow 1- on the inner race -A-.

NOTE:

If the parts are not to be replaced, make sure they are reallocated to their original gear.

Fig 10: Checking 1St, 2Nd And 3Rd Gear Inner Ring For Wear

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-- Press the inner race onto the taper on the gear and measure the gap dimension -a- with a feeler gauge.

Gap Dimension -a-	Installed Dimension	Wear Limit
1st and 2nd gear	0.75 to 1.25 mm	0.3 mm

Fig 11: Checking 1St, 2Nd And 3Rd Gear Synchro-Rings For Wear

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-- Install the synchronizer ring, outer race and inner race onto the taper of the selector gear and then measure the gap dimension -a- with a feeler gauge.

Gap Dimension -a-	Installed Dimension	Wear Limit
1st and 2nd gear	1.2 to 1.8 mm	0.5 mm

Fig 12: Identifying Locking Collar And Locking Pieces With 1st And 2nd Gear Synchro-Hub Components

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1 -

Spring

Assembly in conjunction with hollow locking pieces. Refer to Fig 13.

Assembly in conjunction with locking pieces that are not hollow. Refer to Fig 14.

2 -

Locking collar

3 -

Synchronizer hub

4 -

Locking piece

The collar has the same width on both side of the synchronizer hub.

The shoulder has a chamfer on one side -arrow B-.

The bevel on the synchronizer hub collar and the splines on the outside of the locking collar -arrow A- face in the same direction after being assembled.

The notches on the synchronizer hub and locking collar for the locking pieces -arrow C- must line up.

Fig 13: Assembling Locking Collar/Synchronizer Hub Of 1st And 2nd Gear In Conjunction With Hollow Locking Pieces

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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.

Fig 14: Assembling Locking Collar/Synchronizer Hub Of 1st And 2nd Gear In Conjunction With Locking Pieces That Are Not Hollow

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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 be positioned in front of the locking pieces -arrows-.

Fig 15: Installation Position Of Locking Collar/Synchro-Hub 1st And 2nd Gear

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The teeth of the locking collar -arrow- point toward the splines of the 3rd/4th gear synchronizer hub -A-.

Fig 16: Pressing On Locking Collar/Synchronizer Hub For 1st And 2nd Gear

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

Fig 17: Identifying 1st Gear Outer-Ring Lugs

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The tabs -arrows- face 1st gear -A-.

Fig 18: Identifying Synchro-Ring Lugs & Recesses

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The tabs -arrow 1- engage into the holes -arrow 2- inside the synchronizer ring -B-.

Fig 19: Identifying 2nd Gear Shoulder & Lugs

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The higher collar -A- faces toward 1st gear -B-. The notches in the collar -arrow- lock into the tabs on the outer race. Refer to Fig 17.

Fig 20: Pressing On Inner Race For 3rd Gear Needle Bearing

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Fig 21: Checking 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.

Gap Dimension -a-	Installed Dimension	Wear Limit
1st gear 3rd gear 4th gear	1.0 to 1.7 mm 1.0 to 1.7 mm 1.0 to 1.7 mm	0.5 mm

Fig 22: Disassembling And Assembling 1St And 2Nd As Well As 3Rd And 4Th Gear Locking Collar And Synchro-Hub

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1 -

Spring

Assembly in conjunction with hollow locking pieces. Refer to Fig 13.

Assembly in conjunction with locking pieces that are not hollow. Refer to Fig 14.

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 23: Assembling 1St And 2Nd As Well As 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.

Fig 24: Assembling Locking Collar/Synchronizer Hub Of 3rd And 4th Gear In Conjunction With Locking Pieces That Are Not Hollow

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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 be positioned in front of the locking pieces -arrows-.

Fig 25: Identifying 3rd And 4th Gear Locking Collar/Synchro-Hub Chamfer

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The bevel -arrow- faces 4th gear.

Fig 26: Pressing On 3rd And 4th Gear Synchro-Hub With Locking Collar Using Special Tools VW412, VW519, VW402 & VW447H

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Fig 27: Pressing On Sleeve For 4th Gear Needle Bearing

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Fig 28: Pressing On Sleeve For Output Shaft Needle Bearing

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