Volkswagen Workshop Service and Repair Manuals

Note:

• ◆ Always renew both taper roller bearings and then adjust output shaft
• ◆ When installing new gears, note Technical Data => page 00-4
• ◆ Output shaft gears, removing and installing => page 34-28

Additional bearing for output shaft

Pinion shaft

• Circlip
• ◆ Must fit properly in groove
• Thrust washer
• 5th speed gear
• ◆ Position: Groove upwards
• Gearbox housing
• Output shaft needle bearing
• ◆ Pulling out =>fig. 11 .
• ◆ Pressing in =>fig. 12 .

• 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.
• ◆ Find thickness => page 34-43
• 3rd speed gear
• ◆ Adjust axial play
• ◆ Replace pair only, heat to fit.
• ◆ Shoulder towards 2nd speed gear
• 2nd speed gear
• 2nd speed gear needle bearing
• ◆ Lubricate with gear oil
• Synchro ring for 2nd gear
• ◆ Sprayed with molybdenum
  check for wear =>fig. 1 .

• Spring
• Wire dia. 1.4 mm
• Sleeve
• Hub
• Locking key
• Sleeve/hub for 1st and 2nd gear
• ◆ Assembling =>fig. 3 and 4
  heat to fit
• Synchro ring for 1st gear
• ◆ Check for wear =>fig. 1 .
• ◆ Identification =>fig. 2 .
• 1st speed gear
• Thrust washer
• Shoulder towards taper roller bearing

• Shim S3
• ◆ See => page 39-14
• Outer race, small bearing
• ◆ Pull out =>fig. 9 .
• ◆ Knock in =>fig. 10 .
• Inner race, small bearing
• ◆ Press off =>fig. 6 .
• ◆ Bearing is destroyed, to install heat to 100° C and press home =>fig. 7 .
• Bearing housing
• Output shaft
• Is matched to crown wheel.
• ◆ Adjust if replaced => page 35-31
• Inner race, large bearing
• ◆ Press off =>fig. 5 .
• ◆ Bearing is destroyed, to install heat to 100° C and press home =>fig. 8.
• Bearing plate
• ◆ With bearing outer race and reverse gear stop.
• ◆ Do not press bearing race out.
• 40 Nm

→ Fig.1     Checking synchronizer rings

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

→ Fig.2     Marking of 1st gear synchronizer ring with 110° tooth angle

Identification: 3 x 1 tooth missing -arrow-.

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.

The 1st gear synchronizer ring with full splines - Part No. 014 311 295 D - shown as a service part in the Workshop Manual, is no longer being supplied. In case of repair the synchronizer ring show in the Parts List is to be used.

→ Fig.3     Assembling hub and sleeve for 1st and 2nd gear

Fitting position:
Identification groove on splines - arrow 1 - or end face - arrow 2 - towards 1st gear.

→ Fig.4     Assembling hub and sleeve

• ‒ Push sleeve over hub. It is no longer necessary to fit parts in a
  particular position.
• ‒ Insert keys and install springs 120° offset. The spring with the angled end must engage in the hollow key.

→ Fig.5     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.6     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.7     Heat inner race of small bearing to about 100° C, fit on shaft and press home

→ Fig.8     Heat inner race of large bearing to about 100° C, fit on shaft and press home

→ Fig.9     Pulling outer race of small bearing out of bearing housing

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

→ Fig.10     Knocking outer race of small bearing into bearing

housing

→ Fig.11     Knocking needle bearing out of gearbox housing

→ Fig.12     Knocking needle bearing into gearbox housing