1ST And 2ND Gear Output Shaft

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
• Tube 60 mm Dia. VW 415 A
• Thrust Pad 16.5/28 mm Dia. VW 431
• Arbor 50 mm Dia. VW 432
• Thrust Pad VW 447 i
• Tube 42 mm Dia. VW 516
• Thrust Pad 30-205
• Thrust Piece 40-105
• Thrust Plate 2050
• Thrust Pad 3062
• Press Support 3118
• Thrust Washer 3401
• Kukko Extractor 14.5-18.5 mm 21/2
• Kukko Extractor 46-58 mm 21/7
• Kukko Extractor 56-110 mm 21/89
• Kukko Separating Tool 22-115 mm 17/2
• Kukko Support 22/1
• Kukko Support 22/2
• Kukko Support 22/4
• 2-Arm Puller 20/10
• Thrust Piece T10266
• Feeler Gauge

A - Support, for example 22/1

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

-- Install 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.

-- Remove the locking ring.

-- Switch the locking collar 1st/2nd gear to 1st gear.

-- Attach the pulling hooks under the splines (not selector splines) for the 2nd gear.

A - 2-arm puller, for example 20/10

-- Remove the locking ring.

-- Clamp the output shaft in a vise. Use jaw protectors. -B-.

-- Remove the thrust washer alternating between sides from the output shaft using a drift -C- being careful not to damage the splines.

-- Place the >>larger<< axial needle bearing -2- on the output shaft thrust washer -1-.

• The needles must point upward toward the thrust washer -arrow A- and the flat side -arrow B-.

-- Install the needle bearing -3- and 1st gear -4-.

-- Install the >>smaller<< axial needle bearing -5- on the 1st gear.

• The needles must point upward toward the gear -arrow C- and the flat side -arrow D-.

-- 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

-- 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	1.0 to 1.8 mm	0.5 mm

-- Install the inner race -A- on the 1st 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-.

-- Mount the smaller axial needle bearing (outer diameter: 58.7 mm) -5- on the 1st gear. Refer to Fig 7.

-- Remove the springs -1- for disassembling.

1. Spring
2. Locking piece
3. Locking collar >>installed position<<, refer to Fig 13.
4. Synchronizer hub >>installed position<<, refer to Fig 13.

-- 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.

Different locking collars are installed:

-A-
The chamfer -arrow 1- faces the lower inner collar of synchronizer hub
The shoulder -arrow 2- faces the higher collar on the synchronizer hub

-B-
Collar -arrow 3- and collar -arrow 4- are the same size = installed position.

• 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 high inner collar of the synchronizer hub -arrow- faces the 2nd gear.

Insert the 2nd gear synchronizer ring so that the cut-outs engage in the engagement pieces of locking collar.

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-.

-- Install the 2nd gear needle bearing.

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 15.

-- Install the inner race/tapered roller bearing into the clutch housing. Refer to Fig 22.

A - Support, for example, 22/2

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

-- After removing, install the new shim with the former size under the outer race.

-- Support the transmission housing under the bearing mount using the arbor 50 mm dia. VW 432.

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

-- Install the locking ring.

A - Support, for example 22/4

B - Extractor 56-110 mm, for example 21/89

-- Install the new oil deflector.

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

-- Support the clutch housing using the tube 60 mm dia.VW 415 A directly under the bearing mount.