1ST To 4TH Gear Output Shaft, Disassembling And Assembling

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

Special tools and workshop equipment required

Press Plate: VW401
Press Plate: VW402
Press Piece - Rod: VW407
Press Piece - Rod: VW408A
Press Piece - Multiple Use: VW412
Press Piece - 60mm: VW415A
Holding Plate: VW309A
Holding Fixture: VW313
Transmission Support: VW353
Press Piece - Multiple Use: VW431
Press Piece - Multiple Use: VW433
Press Piece - Multiple Use: VW454
Press Piece - Multiple Use: VW512
Press Piece - 42mm: VW516
Press Piece - Multiple Use: VW519
Slide Hammer Set: VW771
Crankshaft Holding Fixture: VW801
Press Piece - Multiple Use: 40-105
Bearing Installer - Multiple Use: 40-20
Bearing Installer - Differential Bearing: 40-21
Slide Hammer - Press Plate: 2050
Holding Fixture - Spacers: VW540/1B
Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 7: VAG1582/7
Inductive Heater: VAS6414
-1- Internal Puller: VAS251615 (Kukko 21/7)
-1- Puller - Roller Bearing: VAS6775 (Kukko 21-8)
-2- Puller: VAS251419 (Kukko 18-2)
-3- Splitter: VAS251411 (Kukko 17-2)
-4- Counter Support: VAS251623 (Kukko 22/2)

Dished Washer A, Removing from Output Shaft

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Dished Washer, Installing in Output Shaft

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Dimension "a" = 2 mm

Inner Race/Tapered Roller Bearing, Removing on Side facing Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A -

Splitter: VAS251411 (Kukko 17-2)

Inner Race/Tapered Roller Bearing, Installing on Side facing Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Outer Race/Tapered Roller Bearing, Removing from Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter Support: VAS251623 (Kukko 22/2)

B - Puller - Roller Bearing: VAS6775 (Kukko 21-8)

Outer Race/Tapered Roller Bearing, Installing in Clutch Housing

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 with the Bearing Installer - Multiple Use: 40-20 directly under the bearing mount.

Inner Race/Tapered Roller Bearing, Removing on Side facing Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Note the following before installing the Tapered Roller Bearing Puller:

-- Remove the circlip for the inner race/tapered roller bearing on the side facing the transmission housing.

-- Place the : VW431 in the output shaft and lay the : 40-105 on it.

Inner Race/Tapered Roller Bearing, Installing on Side facing Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Determine the correct circlip (refer to Fig 9) and install it.

Circlip, Determining

Fig 9: Determining Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Select and install the thickest circlip that will fit.

NOTE:

Allocate the correct circlips. Refer to the Parts Information.

The following circlips are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Outer Race/Tapered Roller Bearing, Removing from Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - : VAS251623 (Kukko 22/2)

B - : VAS251615 (Kukko 21/7)

Outer Race/Tapered Roller Bearing, Installing in Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the washer under the outer race.

-- Support the transmission housing under the bearing mount using the : 2050 .

Output Shaft, Disassembling

NOTE:

To remove the inner race/tapered roller bearing on the side facing the transmission housing. Refer to Fig 7.

-- Remove the circlip.

3rd and 4th Gear Synchronizer Hub/Locking Collar, Removing with 4th Gear Wheel

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.

A - Puller: VAS251419 (Kukko 18-2)

B - Splitter: VAS251411 (Kukko 17-2)

-- Then remove the retaining ring -item ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Retaining Ring and thrust washers -item ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Thrust Washer.

-- Then remove the 1st gear wheel with synchronizer ring.

On Transmissions with Reinforcement Measures, Remove the Collared Sleeve B Together with the 1st Gear Wheel C.

Fig 13: On transmissions with Reinforcement Measures, Remove the Collar Bushing -B- Together with the 1st Gear Wheel -C-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Splitter: VAS251411 (Kukko 17-2)

-- Install the Separating Tool -A- underneath the helical-cut gear teeth on the 1st gear wheel.

1st and 2nd Gear Locking Collar and Synchronizer Hub, Removing

Fig 14: 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 circlip, remove the 2nd gear wheel and locking collar/synchronizer hub together.

Output Shaft, Assembling

NOTE:

Heat the inner races of the tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) with the Inductive Heat Unit: VAS6414 before installing. Press on as far as the stop so there is no axial play.

Inner Friction Surface on 1st Gear Outer Race, 2nd Gear Outer Race and 3rd Gear Outer Race, Checking for Wear

Fig 15: 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 wheel.

-- Install the outer race -2- on the cone on the inner race. Use a feeler gauge to measure the gap dimension -a- at three places with an offset of 120°.

-- Note the average value.

Wear limit dimension -a-
1st gear, 2nd gear, and 3rd gear	0.4 mm

Outer Friction Surface on 1st Gear Outer Race, 2nd Gear Outer Race and 3rd Gear Outer Race, Checking for Wear

Fig 16: 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 inner contact surface on the synchronizer ring -arrow- for scoring and radial wear. Replace if necessary.

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

-- Press the synchronizer ring with the outer race while turning it at the same time so that synchronizer rings sit correctly.

-- Use a feeler gauge to measure the gap dimension -a- at three places with an offset of 120°.

-- Note the average value.

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

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

2nd Gear Synchronizer Ring, Inner Race and Outer Race, Installing

Fig 17: 1St/2Nd Gear Synchronization From Transmission Build Date 26 October 2009 And 3Rd Gear Synchronization From Transmission Build Date 25 May 2000

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the inner race -A- on 2nd gear wheel.

The tabs -1- face away from the gear wheel.

-- Install the outer race -B-.

The tabs -2- must engage in the gear wheel cut-outs -3-.

-- Install the synchronizer ring -C-.

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

1st/2nd Gear and 3rd/4th Gear Locking Collar and Synchronizer Hub, Disassembling and Assembling

Fig 18: 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.

For the 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.

1st/2nd Gear and 3rd/4th Gear Locking Collar/Synchronizer Hub, Assembling

Fig 19: Assembling 1St And 2Nd As Well As 3Rd And 4Th Gear Locking Collar/Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

1st and 2nd Gear Locking Collar/Synchronizer Hub Installation Position

Fig 20: Identifying Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Warming and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears

Fig 21: Identifying Sequence To Install Locking Collar/Synchronizer Hub For 1st And 2nd Gears

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the circlip.

1st Gear Inner Race, Outer Race and Synchronizer Ring, Installing

Fig 22: Exploded View Of 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- of the synchronizer ring -A-.

Install the 1st Gear Assembly with the Needle Bearing.

Fig 23: 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 -B arrows- in the outer race lock in the recesses -C arrows- in the gear wheel -3-.

-- Install the 1st and 4th gear thrust washers in the output shaft -item ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Thrust Washer and -item ) OVERVIEW - OUTPUT SHAFT, 1ST TO 4TH GEARS - List Item: Retaining Ring.

On transmissions with reinforcement measures, install collar bushing A to stop.

Fig 24: On Transmissions with Reinforcement Measures, Install Collar Bushing -A- to Stop.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installation position of the collared sleeve -A- : The collar -arrow- points to the 1st gear wheel.

-- Then install the 4th gear wheel with needle bearing.

4th Gear Synchronizer Ring, Checking for Wear

Fig 25: 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 Plate Synchronizer Ring
Gap Dimension -a-	Installed Dimension	Wear Limit
4th Gear	1.3 to 2.4 mm	0.8 mm

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

Fig 26: Checking 4Th Gear Synchro-Ring For Wear

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

3rd and 4th Gear Locking Collar/Synchronizer Hub Installation Position

Fig 27: Identifying Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Place the 4th gear synchronizer ring on the 4th gear wheel.

Warming and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears

Fig 28: Identifying Tool Assembly To Press On 3rd And 4th Gear Synchro-Hub With Locking Collar

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Install the circlip.

3rd Gear Inner Race, Outer Race and Synchronizer Ring, Installing

Fig 29: Exploded View Of 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- of the synchronizer ring -A-.

Install the 3rd Gear Assembly with the Needle Bearing.

Fig 30: 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 outer race pins -B arrows- must engage in the openings -C arrows- on the gear wheel -3-.

NOTE:

To install the inner race/tapered roller bearing. Refer to Fig 8.

To determine the correct circlip for the inner race/tapered roller bearing. Refer to Fig 9.