5TH/6TH And Reverse 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
Transmission Support: VW353
Press Piece - Multiple Use: VW433
Press Piece - Multiple Use: VW454
Support Channels: VW457
Crankshaft Holding Fixture: VW801
Press Piece - Multiple Use: VW431
Press Piece - Multiple Use: VW455
Press Piece - Multiple Use: VW510
Press Piece - 42mm: VW516
Press Piece - Multiple Use: VW519
Press Piece - Multiple Use: 30-11
Press Piece - Multiple Use: 40-105
Bearing Installer - Multiple Use: 40-20
Slide Hammer - Press Plate: 2050
Press Piece - Reverse Gear Syncro: 3296
Puller - Taper Roller Bearing: VAG1582
Puller - Taper Roller Bearing - Adapter 4: VAG1582/4
Puller - Taper Roller Bearing - Adapter 7: VAG1582/7
Inductive Heater: VAS6414
-1- Internal Puller: VAS251615 (Kukko 21/7)
-3- Splitter: VAS251411 (Kukko 17-2)
-4- Counter Support: VAS251623 (Kukko 22/2)

Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

B - Internal Puller: VAS251615 (Kukko 21/7)

NOTE:

Check the washer for damage after removing it and replace if necessary.

Outer Race/Tapered Roller Bearing, Installing in Clutch Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the washer under the outer race.

-- Support the clutch housing with the : 40-20 directly under the bearing mount.

Outer Race/Tapered Roller Bearing, Removing from Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

B - Internal Puller: VAS251615 (Kukko 21/7)

Outer Race/Tapered Roller Bearing, Installing in Transmission Housing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Output Shaft, Disassembling

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

Fig 5: Identifying Tool Assembly To Remove 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 Press Piece - Multiple Use: VW431 and Press Piece - Multiple Use: 40-105 on the output shaft.

5th/6th Gear Synchronizer Hub/Locking Collar with 6th Gear Wheel, Removing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the circlip beforehand.

Removing the Sleeve A Together with the Reverse Gear Wheel

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the circlip beforehand.

Reverse Gear Synchronizer Hub, Removing

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the circlip beforehand.

A - Splitter: VAS251411 (Kukko 17-2)

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Mount the Press Piece - Multiple Use: 30-11 on the output shaft before mounting the puller.

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.

Reverse Gear Synchronizer Hub Installation Position

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Warming and Installing the Reverse Gear Synchronizer Hub

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the circlip.

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

-- Install the reverse gear wheel with the needle bearing.

Sleeve A, Installing

Fig 12: Identifying Tools To Install Sleeve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installation position: the wider collar faces the reverse gear wheel.

-- Install the circlip.

5th and 6th Gear Synchronizer Ring, Checking for Wear

Fig 13: 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
5th and 6th gear	1.0 to 1.7 mm	0.5 mm

-B- = Steel Synchronizer Ring
Gap Dimension -a-	Installed Dimension	Wear Limit
5th and 6th gear	1.2 to 2.1 mm	0.8 mm

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

Fig 14: Checking 4Th Gear Synchro-Ring For Wear

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

5th and 6th Gear Synchronizer Hub and Locking Collar, Disassembling and Assembling

Fig 15: 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.

-- To disassemble, remove the springs -1-.

Spring
Locking Piece
Locking Collar
Synchronizer Hub

-- Slide the locking collar over the synchronizer hub.

Installed position: The narrow locking piece recesses in the synchronizer hub align with the recesses in the locking collar.

5th and 6th Gear Locking Collar/Synchronizer Hub, Assembling

Fig 16: 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.

-- Install the 6th gear assembly with the needle bearing.

-- Install the 6th gear synchronizer ring.

5th and 6th Gear Locking Collar/Synchronizer Hub, Installing

Fig 17: Identifying Tools To Install 5th And 5th Gear Locking Collar/Synchro-Hub

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Installation position: the bevel on the outer diameter of the locking collar faces toward the 5th gear wheel.

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

-- Install the circlip.

-- Install the 5th gear synchronizer ring.

-- Install the 5th gear assembly with the needle bearing.

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

Fig 18: Identifying Tools To Press On Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Determine the correct circlip (refer to Fig 19) and install it.

Circlip, Determining

Fig 19: Determining Circlip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Select the appropriate circlip according to the table. Part number. Refer to the Parts Information.

Available Circlips:

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	1.95

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

Fig 20: Identifying Tool Assembly To Install Inner Race/Tapered Roller Bearing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.