Volkswagen Workshop Service and Repair Manuals

Note:

Always renew both bearings and then adjust output shaft,

When installing new gears, note Technical Data, => page 00-3

Securing the output shaft needle roller bearing, => page 35-50

• Gearbox housing
• Output shaft needle bearing
• ◆ Pulling out =>Fig. 17
• ◆ Pressing in =>Fig. 18
• Stop for needle bearing
• Circlip
• ◆ Fit new, must seat properly in groove.
• 4th speed gear
• ◆ Replace pair only, heat to fit. Shoulder upwards.

• Circlip
• ◆ Fit new, must seat properly in groove =>Fig.8
• 3rd speed gear
• ◆ Adjust axial play =>Fig. 8 , replace pair only, heat to fit.
• ◆ Shoulder towards 2nd speed gear.
• 2nd speed gear
• 2nd speed gear bearing
• ◆ Install needle bearing inner race and knock home=>Fig. 7
• Synchro ring for 1st and 2nd gear
• ◆ Check for wear =>Fig.2
• ◆ Mod. =>Fig.3
• Spring
• ◆ Mod.
• Sleeve
• Hub

• Locking key
• Sleeve/hub for 1st and 2nd gear
• ◆ Remove reverse gear shaft before removing, pulling off =>Fig. 1
• ◆ Assembling =>Fig. 4 and =>Fig.5
• ◆ Heat to fit, drive home =>Fig. 6
• ◆ Mod.
• 1 st speed gear
• thrust washer
• Shoulder towards taper roller bearing
• Reverse gear
• Shoulder downwards.
• Reverse gear shaft
• ◆ Knock out and in with plastic hammer align =>Fig. 10
• Bush
• (Up to 15 06 5)
• ◆ Mod.=> page 34-69
• ◆ Location => Fig.9

• Shim S3
• ◆ See
• Outer race, small bearing
• ◆ Pull out =>Fig.15
• ◆ Knock in =>Fig. 16
• Bearing housing
• Inner race, small bearing
• ◆ Press off =>Fig.12 , bearing is destroyed
• ◆ To install heat to 100°C and press home =>Fig. 13
• Output shaft
• ◆ Is matched to crown wheel adjust if replaced
• Inner race, large bearing
• ◆ Press off =>Fig.11 bearing is destroyed
• ◆ To install, heat to 100°C and press home =>Fig.14

• Outer race, large bearing with end cover
• ◆ Is installed in end cover, do not press race out. Mod.
• Reinforcement plate
• ◆ Mod.
• Self-locking nuts 25 Nm
• ◆ Mod.

→ Fig.1     Pulling off hub/sleeve and 1st speed gear

•      1 -     Two-arm puller such as Kukko 10-20 with 250 mm long hooks.

→ Fig.2     Checking synchronizer rings

Press synchro rings on to gear cones and measure gap "a" with feelers.

Mod:

From 20 10 6

Tooth angle on 1st gear ring changed form 120° to 110°. (2 - 4 gears still 120°).

→ Fig.3     Marking of 1st gear cynchronizer ring with 110°

Identification:

3 x 1 tooth missing -arrow- (interim period: 3 x 3 teeth)

This ring must only be installed on 1st gear.

When renewing 1st gear ring:

Use ring - Part No. 014 311 295 D - with full teeth.

→ Fig.4     Assembling hub and sleeve for 1st and 2nd gear

Fitting position for synchro hub for 1st/2nd gear

From gearbox 27 07 6

Identification groove for 1st gear side moved from splines -arrow 1- to end face -arrow 2- so that it can be seen when parts are assembled.

Position unchanged: Groove towards 1st gear.

Modification:

Locking key springs 1st - 4th gears

From gearbox 28 09 6

Wire diameter reduced from 1.6 to 1.4 mm (reduces shifting force). New springs can be installed in earlier synchromesh units.

→ Fig.5     Assembling sleeve/hub

• ‒ Place sleeve on hub. The parts need not be fitted in a particular position.
• ‒ Insert keys and install springs 120° offset. The angled end of the spring must engage in the hollow key.

→ Fig.6     Heat the needle bearing inner race to about 120° C, place it on shaft and drive it fully home

Fitting direction:

• ‒ Turn synchronizer rings so that grooves align with keys.

→ Fig.7     Drive needle bearing inner race fully home

→ Fig.8     Adjusting axial play of 3rd speed gear

• ‒ Measure axial play with a feeler gauge and adjust it by selecting a suitable circlip. The play should be between 0 and 0.20 mm. Keep as near as possible to lower limit.
• ‒ Install circlip with pliers VW 161 a.

Circlips are available in the following thickness:

→ Fig.9     Installing stop bush

Heat bush before installing

-a- = 41 mm

→ Fig.10     Aligning reverse gear shaft

Dimensions x should be the same.

→ Fig.11     Pressing off inner race of large bearing

A - Parting appliance such as Kukko 17/2 - 22 to 115 mm.

Bearing is destroyed in the process.

→ Fig.12     Pressing off inner race of small bearing

A - Parting appliance such as Kukko 17/2 - 22 to 115 mm.

Bearing is destroyed in the process.

→ Fig.13     Heat inner race of small bearing to about 100 °C, fit on shaft and press home

→ Fig.14     Heat inner race of large bearing to about 100° C, fit on shaft and press home

→ Fig.15     Pulling outer race of output shaft out

•      A -     Extractor 37 - 46 mm, Kukko 21/6
•      B -     Support from Kukko 22/2

→ Fig.16     Knocking in outer race of small bearing

→ Fig.17     Removing output shaft needle bearing

•      1 -     Extractor 18.5 - 23.5 mm, Kukko 21/3

→ Fig.18     Knocking in output shaft needle bearing