Output Shaft 1, Assembling: Procedure

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

This procedure shows how the output shaft 1 is assembled. For the following procedures on the press the shaft bearing may not be damaged.

If the bearing is not replaced it must be protected.

When installing the bearing for each pressing procedure the Press Piece - Multiple Use :VW 447i must also be used.

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Removing the bearing. Refer to Removing the Output Shaft 1 Bearing .
Installing the bearing. Refer to Installing the Output Shaft 1 Bearing .

-- Place the needle bearing on the output shaft.

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-- Pay attention that the cage is not broken.

-- Coat the bearing with oil.

-- Place the gear wheel for the 2nd gear on the needle cage.

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-- Coat the friction surface with oil.

-- Place both synchronizer rings with the outer race on the 2nd gear wheel.

-- Position the locking collar on the synchronizer hub. At the same time the groove for the shift fork points >>upward<<, the collar of the shift fork >>downward<<.

The synchronizer hub can only be positioned. It is installed in the next step.

-- Install the synchronizer hub.

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NOTE:

While pressing on, pay attention to two things:

Lift the gear and at the same time do not turn. The synchronizer ring is in its installation position, before the synchronizer hub clamps the ring.

After the ring has found its seat press on only until more force is felt. Then immediately stop pressing. The gear wheel for the 2nd gear must have axial play. The wheel has its installation position as soon as the force is increased while pressing. If pressed in further the synchronizer hub is pressed against the needle bearing and damaged.

After pressing turn the gear wheel in the horizontal position of the shaft >>free<<.

-- Install the needle bearing sleeve from the 4th gear wheel.

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Installation direction: lettering faces >>downward<<.

NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

-- Install the needle bearing.

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-- Coat the bearing with oil.

-- Coat the friction surface with oil.

-- Position the large synchronizer ring, outer race and small synchronizer ring.

-- Position the 4th gear wheel.

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-- Install the washer.

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NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

After pressing turn the gear wheel in the horizontal position of the shaft >>free<<.

To press in the output shaft the shaft is assembled up to this washer.

WARNING:

First assemble the output shaft when the transmission is adjusted. Refer to OUTPUT SHAFT, ADJUSTING .

-- Install the needle bearing sleeve from the 3rd gear wheel.

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NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

-- Install the needle bearing.

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-- Coat the bearing and friction surfaces with oil.

-- Position the 3rd gear wheel, small synchronizer ring, outer race and large synchronizer ring.

-- Install the locking collar and synchronizer hub.

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NOTE:

While pressing on, pay attention to two things:

Lift the gear and at the same time do not turn. The synchronizer ring is in its installation position, before the synchronizer hub clamps the ring.

After the ring has found its seat press on only until more force is felt. Then immediately stop pressing. The 3rd gear wheel must have axial play. The wheel has its installation position as soon as the force is increased while pressing. If pressed in further the synchronizer hub is pressed against the needle bearing and damaged.

After pressing turn the gear wheel in the horizontal position of the shaft >>free<<.

-- Install the needle bearing sleeve from the 1st gear wheel.

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NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

-- Install the needle bearing.

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-- Coat the bearing and friction surfaces with oil.

-- Then place the small synchronizer ring on the 1st gear wheel.

-- Then the outer race and then the large synchronizer ring.

The gear and shaft can be installed together on the shaft.

-- Install the washer.

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NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

After pressing turn the gear wheel in the horizontal position of the shaft >>free<<.

-- Install the bearing.

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NOTE:

Also immediately stop pressing here, when an increase in force can be felt when pressing in. Do not press in again.

-- Coat the bearing with oil.

-- Install new bolt and tighten.

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