Output Shaft, 1st To 4th Gears

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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
Holding Plate VW 309
Holding Fixture VW 313
Transmission Support VW 353
Thrust Pad 16.5/28 mm Dia. VW 431
Thrust Pad Con. 8/65 VW 433
Thrust Tube VW 454
Thrust Pad VW 512
Tube 42 mm Dia. VW 516
Sleeve VW 519
Slide Hammer-Complete Set VW 771
Holding Fixture VW 801
Thrust Piece 40-105
Sleeve 40-20
Sleeve 40-21
Thrust Plate 2050
Spacers VW 540/1B
Tapered Roller Bearing Puller VAG 1582
Grip VAG 1582/7
Inductive Heat Unit VAS 6414
Kukko Extractor 46-58 mm 21/7
Kukko Extractor 56-70 mm 21/8
Kukko Puller 80-210 mm 18/2
Kukko Separating Tool 22-115 mm 17/2
Kukko Support 22/2

Fig 1: Identifying Tools To Pull Dished Washer Out Of Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 2: Identifying Tool To Press Dished Washer Into Output Shaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-a- = 2 mm

Fig 3: Identifying Kukko Separating Tool Assembly To Press Off Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Tool Assembly To Press On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 5: Identifying Kukko Tool Assembly To Pull Out Tapered Roller Bearing Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter support, for example, Kukko support 22/2

B - Internal puller 56 to 70 mm, for example, Kukko extractor 56-70 mm 21/8

Fig 6: Identifying Tool Assembly To Press Outer Race/Tapered Roller Bearing Into Clutch Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Support the clutch housing using the sleeve 40-20 directly under the bearing mount.

Fig 7: Identifying Tool Assembly To Pull Off Inner Race/Tapered Roller Bearing

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Before installing the tapered roller bearing puller:

-- Remove the bearing inner race/tapered roller bearing locking ring on the side facing the clutch housing.

-- Install the thrust pad 16.5/28 mm dia. VW 431 in the output shaft and lay the thrust piece 40-105 on it.

Fig 8: Identifying Tool Assembly To Press On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Choose the correct locking ring, refer to Fig 9 and install.

Fig 9: Determining Circlip

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-- Choose and install the thickest locking ring that will fit.

NOTE:

Use the correct locking rings

The Following Locking Rings Are Available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Fig 10: Identifying Tapered Roller Bearing Outer Race Pulled Out From Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter support, for example, Kukko support 22/2

B - Internal puller 46 to 58 mm, for example, Kukko extractor 46-58 mm 21/7

Fig 11: Identifying Tapered Roller Bearing Outer Race Pressed Into Transmission Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the adjusting shim under the outer race.

-- Support the transmission housing under the bearing mount using the thrust plate 2050.

Disassembling the Output Shaft

NOTE:

Removing the bearing inner race/tapered roller bearing on the side of the clutch housing. Refer to Fig 7.

Fig 12: Identifying Puller/Separator Assembly To Pull Off 3rd And 4th Gear Synchro-Hub/Locking Collar Over 4th Gear Wheel

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the locking ring beforehand.

A - Puller, for example, Kukko puller 80-210 mm 18/2

B - Separating tool 22 to 115 mm, for example, Kukko separating too 22-115 mm 17/2

Fig 13: Identifying Tool Assembly To Press Off 1st And 2nd Gear Locking Collar And Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

After removing the locking ring, press off the selector gear for 2nd gear and the locking collar/synchronizer hub together.

Assembling the Output Shaft

NOTE:

Heat the tapered roller bearing inner races and synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit VAS 6414 before installing. Press on until seated when installing, so there is no axial clearance.

Fig 14: Checking Inner Contact Surface For Wear On 1st Gear Outer Race And On 2nd Gear Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the inner race -1- on the cone on the gear.

-- Install the outer race -2- on the cone on the inner race. Measure the gap -a- with a feeler gauge at 3 locations 120° apart.

-- Note the average value.

Wear Limit Dimension -a-
1st, 2nd, and 3rd gear	0.4 mm

Fig 15: Checking Outer Contact Surface For Wear On 1st Gear Outer Race And On 2nd Gear Outer Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the synchronizer ring -arrow- on the inner running surface for grooves and radial wear, and replace if necessary.

-- Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.

-- Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.

-- Measure the gap -a- with a feeler gauge at 3 locations 120° apart.

-- Note the average value.

Wear Limit Dimension -a-
1st, 2nd, and 3rd gear	0.8 mm

-- Install the 2nd gear with the needle bearing.

Fig 16: 1st/2nd Gear Synchronization From Transmission Build Date 26 October 2009 And 3rd Gear Synchronization From Transmission Build Date 25 May 2000

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-- Place the inner race -A- on the drive gear for 2nd gear.

The tabs -1- face away from the gear.

-- Install the outer race -B-.

The tabs -2- engage in the grooves -3- on the gear.

-- Install the synchronizer ring -C-.

The larger openings -4- lock in the tabs -1- on the inner race -A-.

Fig 17: Disassembling And Assembling 1st And 2nd As Well As 3rd And 4th Gear Locking Collar And Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Spring
Locking piece
Locking collar
Synchronizer hub

-- Slide the locking collar over the synchronizer hub.

In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Fig 18: Assembling 1st And 2nd As Well As 3rd And 4th Gear Locking Collar/Synchro-Hub

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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.

Fig 19: Identifying Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-Hub

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The identification groove -arrow 1- and the narrow collar -arrow 2- on the synchronizer hub face 1st gear.

Fig 20: Identifying Sequence To Install Locking Collar/Synchronizer Hub For 1st And 2nd Gears

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The pins -A- on the synchronizer ring lock into the recesses -B- in the synchronizer hub.

-- Install the locking ring.

Fig 21: Identifying Sequence To Install Outer Ring Synchronizer Ring And 1st Gear Outer Race and Inner Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the synchronizer ring -A- into the 1st and 2nd gear synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

-- Install the outer race -B- in the synchronizer ring.

The tabs -3- face away from the synchronizer ring.

-- Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Fig 22: Identifying Installation Of 1st Gear With Needle Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.

-- Install the 1st and 4th gear thrust washers -items 19 and 20- in OUTPUT SHAFT, 1ST TO 4TH GEARS OVERVIEW in the output shaft.

-- Install the 4th gear with needle bearing.

Fig 23: Checking 4th Gear Synchronizer Ring For Wear

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-A- = Brass Synchronizer Ring
Gap Dimension -a-	Installed Dimension	Wear Limit
4th gear	1.0 to 1.7 mm	0.5 mm

-B- = Steel Synchronizer Ring
Gap Dimension -a-	Installed Dimension	Wear Limit
4th gear	1.3 to 2.4 mm	0.8 mm

-- Press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.

Fig 24: Checking 4th Gear Synchro-Ring For Wear

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Fig 25: Identifying Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub

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The wider collar on the synchronizer hub -arrow- faces 3rd gear.

-- Place the synchronizer ring for 4th gear on the 4th gear selector gear.

Fig 26: Identifying Tool Assembly To Press On 3rd And 4th Gear Synchro-Hub With Locking Collar

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-- Turn the 4th gear synchronizer ring so that the grooves line up with the locking pieces.

-- Install the locking ring.

Fig 27: Identifying Sequence To Install Outer Ring Synchronizer Ring And 1st Gear Outer Race and Inner Race

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the synchronizer ring -A- into the 3rd and 4th gear synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

-- Install the outer race -B- in the synchronizer ring.

The tabs -3- face away from the synchronizer ring.

-- Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Fig 28: Identifying Installation Of 1st Gear With Needle Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear -3-.

-- Install the 3rd gear with the needle bearing.

NOTE:

Installing the bearing inner race/taper roller bearing, refer to Fig 8.

Selecting the locking ring for the bearing inner race/tapered roller bearing. Refer to Fig 9.