Reverse Gear Output Shaft

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 408 A
Thrust Disc VW 412
Thrust Tube VW 454
Thrust Pad 16.5/28 mm Dia. VW 431
Press Appliance VW 459
Split Tube VW 463/2
Thrust Piece VW 473
Tube 42 mm Dia. VW 516
Press Support 3118
Front and Rear Bearing Tool 3348
Thrust Washer 3401
Tapered Roller Bearing Puller V.A.G 1582
Attachment to V.A.G 1582 V.A.G 1582/4
Tube Trans. Drive Shaft VW 426
Kukko Extractor 14.5-18.5 mm 21/2
Kukko Extractor 37-46 mm 21/6
Kukko Extractor 46-58 mm 21/7
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/1
Base Block VW 441
Gearbox Holder 2004/1

Fig 1: Remove the Dished Washer -C- from the Output Shaft

Courtesy of AUDI OF AMERICA, LLC

A - Support, for example Kukko 22/1

B - Extractor 14.5-18.5 mm, for example 21/2

NOTE:

If the extractor comes out of the hole in the dished washer, then use the next larger extractor.

Fig 2: Install the Dished Washer -A- All the Way into the Output Shaft -B-.

Courtesy of AUDI OF AMERICA, LLC

-- Mount the thrust washer 3401 with the shoulder -arrow- on the dished washer -A-.

Press-in depth for the dished washer is approximately 2.20 mm.

Fig 3: Removing Inner Race/Tapered Roller Bearing In Transmission Housing

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

-- Remove the locking ring.

Fig 4: Removing Synchronizer Hub/Reverse Gear And Reverse Gear Wheel

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-- Mount the reverse gear with the needle and roller bearings on the output shaft.

Installed Position of the Synchronizer Hub for Reverse Gear

The stop -arrow- faces the pressing tool.

Fig 5: Pressing On Synchronizer Hub For Reverse Gear

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-- Pressing on the synchronizer hub for the reverse gear.

-- Install the locking ring.

Fig 6: Removing Inner Race/Tapered Roller Bearing In Clutch Housing

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-- Before installing the puller, set the thrust pad 16.5/28 mm dia.VW 431 onto the output shaft.

Fig 7: Installing Inner Race/Tapered Roller Bearing In Clutch Housing

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Fig 8: Removing Outer Race/Tapered Roller Bearing From Clutch Housing

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-- Mount the sleeve VW 459/1 over the bearing seat with collar facing the support -A-.

A - Support, for example 22/2

B - Extractor 46-58 mm, for example 21/7

After removing, replace the damaged shim.

-- Install the oil deflector.

-- Install the new shim with the former size.

Fig 9: Installing Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of AUDI OF AMERICA, LLC

-- Support the clutch housing directly beneath the bearing mount using the thrust piece VW 473.

Fig 10: Installing Inner Race/Tapered Roller Bearing In Transmission Housing

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NOTE:

Removing the inner race/tapered roller bearing inside the transmission housing. Refer to Fig 3.

Fig 11: Removing Outer Race/Tapered Roller Bearing From Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

The collar on the press support 3118 faces the support -A-.

A - Support, for example 22/2

B - Extractor 37-46 mm, for example 21/6

-- Install the new shim of the former size under the outer race.

Fig 12: Installing Outer Race/Tapered Roller Bearing Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

-- Support the transmission housing beneath the bearing mount using the split tube VW 463/2.

When positioning the split tube VW 463/2 be careful of the housing rib.

The perforation in the base block VW 441 -arrow- faces the split tube VW 463/2.