Output Shaft 2, Assembling: Procedure

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

This procedure shows how the output shaft 2 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 447H must also be used.
Removing the bearing. Refer to OUTPUT SHAFT 2, DISASSEMBLING - Removing the output shaft 2 bearing .
Installing the bearing. Refer to OUTPUT SHAFT 2, DISASSEMBLING - Installing the output shaft 2 bearing .

-- Place the both needle bearings on the output shaft.

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-- Pay attention that the cage is not damaged.

-- Coat the bearing with oil.

-- Position the reverse drive gear.

-- Position the reverse drive gear, axial bearing >>with the flat side facing upward<<.

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-- Position the locking collar on the synchronizer hub. At the same time the surrounding sleeve edge points >>upward<< and the collar of the locking collar >>downward<<.

Disassembling and assembling the locking collar. Refer to LOCKING COLLARS AND SYNCHRONIZER HUB FOR OUTPUT SHAFT 2, DISASSEMBLING AND ASSEMBLING .

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

-- Install the synchronizer hub.

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NOTE:

Immediately stop pressing when an increase in force can be felt when pressing in. Do not press in again.

-- Press on the sleeve for the 6th gear wheel.

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-- Position the synchronizer ring, needle bearing and 6th gear wheel.

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-- Coat the bearing and friction surfaces with oil.

-- Press on the washer for the 6th gear wheel.

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If there is lettering on the washer, then position this side >>downward<<.

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 7th 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.

-- Position the needle bearing, 7th gear wheel and synchronizer ring.

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-- Coat the bearing and friction surface with oil.

-- Position the locking collar on the synchronizer hub. At the same time the surrounding sleeve edge points >>upward<< and the collar of the locking collar >>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 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 5th 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.

-- Position the synchronizer ring, needle bearing and 5th gear wheel.

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-- Coat the bearing and friction surface with oil.

-- Install the bearing.

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-- Coat the bearing with oil.

-- Install new bolt and tighten.

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