Output Shaft, 5th, 6th And Reverse Gears

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
• Transmission Support VW 353
• Thrust Pad Con. 8/65 VW 433
• Thrust Tube VW 454
• Support Channels VW 457
• Holding Fixture VW 801
• Thrust Pad 16.5/28 mm Dia. VW 431
• Thrust Tube VW 455
• Thrust Pad VW 510
• Tube 41 mm Dia. VW 516
• Sleeve VW 519
• Thrust Pad 30-11
• Thrust Piece 40-105
• Sleeve 40-20
• Thrust Plate 2050
• Tube 3296
• Tapered Roller Bearing Puller VAG 1582
• Attachment to VAG 1582 VAG 1582/4
• Grip VAG 1582/7
• Inductive Heat Unit VAS 6414
• Kukko Extractor 46-58 mm 21/7
• Kukko Separating Tool 22-115 mm 17/2
• Kukko Support 22/2

Procedure 

Fig 1: Identifying Support/Puller/Extractor Assembly To Remove Tapered Roller Bearing Outer Race

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 2: Identifying Tool Assembly To Install Outer Race/Tapered Roller Bearing Into Clutch Housing

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-- Place the washer under the outer race.

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

Fig 3: Identifying Outer Race/Tapered Roller Bearing Pulled Out Of Transmission Housing

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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 4: Identifying Outer Race/Tapered Roller Bearing Pressed Into Transmission Housing

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

Disassembling the Output Shaft 

Fig 5: Identifying Tool Assembly To Remove Inner Race/Tapered Roller Bearing

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Note the following before installing the Tapered Roller Bearing Puller VAG 1582: 

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

-- Mount the thrust pad 16.5/28 mm dia. VW 431 and thrust piece 40-105 on the output shaft.

Fig 6: Identifying Tools To Remove 5th And 5th Gear Synchro-Hub/Locking Collar With 5th Gear

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-- Remove the locking ring beforehand.

Fig 7: Identifying Tool Assembly To Remove Sleeve -A- Over Reverse Gear Wheel

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-- Remove the locking ring beforehand.

Fig 8: Identifying Tools To Remove Reverse Gear Synchro-Hub

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-- Remove the locking ring beforehand.

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

Fig 9: Identifying Tool Assembly To Remove Inner Race/Tapered Roller Bearing

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-- Mount the thrust pad 30-11 on the output shaft before removing the puller.

Assembling the Output Shaft

Fig 10: Identifying Installation Position Of Reverse Gear Synchro-Hub

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The stop -arrow A- on the reverse gear locking collar faces the splines on the output shaft -arrow B-.

Fig 11: Identifying Tools To Press On Reverse Gear Synchro-Hub

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-- Install the locking ring.

-- Mount the reverse gear locking collar on the reverse gear synchronizer hub.

-- Install the reverse gear and the needle bearing.

Fig 12: Identifying Tools To Install Sleeve

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Installed position: The wide collar points toward reverse gear selector gear.

-- Install the locking ring.

Fig 13: Checking 4th Gear Synchro-Ring For Wear

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

Fig 14: Disassembling And Assembling 1st And 2nd As Well As 3rd And 4th Gear Locking Collar And Synchro-Hub

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1. Spring
2. Locking Piece
3. Locking Collar
4. Synchronizer Hub

-- Slide the locking collar over the synchronizer hub.

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

Fig 15: 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.

-- Install the 6th gear with needle bearing.

-- Install the 6th gear synchronizer ring.

Fig 16: Identifying Tools To Install 5th And 5th Gear Locking Collar/Synchro-Hub

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On some locking collars, there is a chamfer on the outer diameter.

Installed position: The chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear

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

-- Install the locking ring.

-- Install the 5th gear synchronizer ring.

-- Install 5th gear selector gear with needle bearing.

Fig 17: Identifying Tools To Press On Inner Race/Tapered Roller Bearing

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-- Choose the correct locking ring, refer to Fig 18 and install.

Fig 18: Determining Circlip

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

-- Select the locking ring according to the table.

Available Locking Rings 

Fig 19: Identifying Tool Assembly To Install Inner Race/Tapered Roller Bearing

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