3RD And 4TH Gear Output Shaft
Special tools and workshop equipment required
- Thrust Plate VW 401
- Thrust Plate VW 402
- Punch VW 407
- Thrust Disc VW 412
- Tube 60 mm Dia. VW 415 A
- Thrust Pad 16.5/28 mm Dia. VW 431
- Thrust Pad Con. 8/65 VW 433
- Thrust Tube VW 454
- Support Channels VW 457
- Thrust Pad VW 510
- Sleeve VW 519
- Holding Fixture VW 801
- Thrust Pad 30-11
- Thrust Piece 40-105
- Press Support 3118
- Tapered Roller Bearing Puller V.A.G 1582
- Attachment to V.A.G 1582 V.A.G 1582/4
- Grip V.A.G 1582/7
- Kukko Extractor 46-58 mm 21/7
- Kukko Extractor 56-70 mm 21/8
- Kukko Support 22/2
- Feeler Gauge
-- Mount the thrust pad 16.5/28 mm dia. VW 431 in the output shaft and lay the thrust plate 40-105 on top of it before installing the puller.
-- Remove the locking ring.
-- Place the tools under the 3rd gear so that no other components can get damaged during removal.
When removing, if the 5th gear is just in front of the -arrow-, then secure the output shaft from falling down.
-- Remove the locking ring.
-- 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 |
|---|---|---|
| 3rd and 4th gear | 0.75 to 1.25 mm | 0.3 mm |
-- Install the synchronizer ring, outer race and inner race onto the taper of the elector gear and then measure the gap dimension -a- with a feeler gauge.
| Gap Dimension -a- | Installed Dimension | Wear Limit |
|---|---|---|
| 3rd gear | 1.0 to 1.8 mm | 05 mm |
| 4th gear | 1.0 to 1.9 mm | 0.5 mm |
-- Install the 4th gear with needle bearing.
-- Install the inner race -A- on the 4th gear.
- The angled tabs -arrows 1- face the outer race -B-.
-- Install the outer race -B-.
- The tabs -arrows 2- must lock into the retainers -arrows 3- in the gear.
-- Install the synchronizer ring -C-.
- The retainers -arrows 4- lock in the braces -arrows 1- on the inner race -A-.
-- Remove the springs -1- for disassembling.
- Spring
- Locking piece
- Locking collar
- Synchronizer hub >>installed position<<, refer to Fig 10.
-- Slide the locking collar over the synchronizer hub.
- Installed position: The narrow recesses in the synchronizer hub align with the recesses in the locking collar.
- 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.
The taller collar of the synchronizer hub -arrow- faces 4th gear.
- The 4th gear is mounted on the shaft with the needle bearing and the synchronizer rings.
-- Install the locking ring.
The tabs -arrows- face the synchronizer hub/locking collar -A-.
The tabs -arrows 1- engage into the holes -arrows 2- inside the synchronizer ring -B-.
The higher collar -A- faces toward 4th gear -B-. The notches in the collar -arrow- lock into the tabs on the outer race. Refer to Fig 12.
-- Install the 3rd gear with the needle bearing.
-- Heat the 5th gear to approximately 150 °C (302 °F).
-- Press the gear on quickly so that heat is not also transferred onto output shaft.
-- Heat the 6th gear to approximately 150 °C (302 °F).
-- Insert the circlip.
If, in the previous step, the 5th gear has been mounted, allow the output shaft to cool down.
-- Press the gear on quickly so that heat is not also transferred onto output shaft.
-- Install the circlip for the 6th gear.
Removing the inner race/tapered roller bearing inside the transmission housing. Refer to Fig 1.
A - Support spindle, for example 22/2
B - Extractor 46-58 mm, for example 21/7
-- Install the new shim with the former size under the outer race.
-- Mount the thrust pad 30-11 on the output shaft before removing the puller.
A - Support, for example 22/2
B - Extractor 56-70 mm, for example 21/8
-- Install the new shim of the former size under the outer race.
-- Support the clutch housing with the tube 60 mm dia.VW 415 A directly under the bearing mount.