Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 1st through 4th gears

Special tools and workshop equipment required

t	Pressure plate -VW 401-

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support plate -VW 309-

t	Support clamp -VW 313-

t	Gearbox support -VW 353-

t	Thrust piece -VW 431-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Thrust pad -VW 512-

t	Tube -VW 516-

t	Tube -VW 519-

t	Multipurpose tool -VW 771-

t	Support plate -VW 801-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Drift sleeve -40-21-

t	Thrust piece -2050-

t	Supplementary set for engine and gearbox support -VW 540/1 B-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/7-

t  Internal puller -1- Kukko 21/7- t  Internal puller -1- Kukko 21/8- t  Puller -2- Kukko 18/2- t  Splitter -3- Kukko 17/2- t  Counter support -4- Kukko 22/2-   Note t  If output shaft or tapered roller bearings have been renewed, adjust output shaft → Chapter. t  Always renew both tapered roller bearings together as a set.

1 -	Clutch housing

2 -	Oil deflector ring

3 -	Dished washer

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

5 -	Tapered roller bearing inner race

q	Pressing off → Fig.

q	Pressing on → Fig.

6 -	Output shaft

q	For 1st through 4th gears

q	Adjusting → Chapter

7 -	Needle bearing

q	For 2nd gear

8 -	Synchromeshed gear for 2nd gear

9 -	Synchro-ring

q	(Inner ring for 2nd gear)

q	Check for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

10 -	Outer ring for 2nd gear

q	Place on synchro-ring → Item

q	Renew if scored

q	Installation position → Fig.

11 -	Synchro-ring for 2nd gear

q	Check for wear → Fig.

q	Installation position → Fig.

12 -	Locking collar with synchro-hub for 1st and 2nd gears

q	After removing retaining ring → Item, press off with synchromeshed gear for 2nd gear → Fig.

q	Dismantling → Fig.

q	Assembling locking collar and synchro-hub → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

13 -	Retaining ring

14 -	Synchro-ring for 1st gear

q	Check for wear → Fig.

q	Assemble so that notches engage in locking pieces of locking collar → Item

15 -	Outer ring for 1st gear

q	Insert in synchro-ring → Item; installation position → Fig.

q	Renew if scored

16 -	Synchro-ring

q	(Inner ring for 1st gear)

q	Check for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

17 -	Needle bearing

q	For 1st gear

18 -	Synchromeshed gear for 1st gear

q	Installation position → Fig.

19 -	Thrust washer

q	For 1st through 4th gears

q	Insert lugs on thrust washer in hole of output shaft.

20 -

Washer

q	Holds thrust washers → Item on output shaft.

21 -	Needle bearing

q	For 4th gear

22 -	Synchromeshed gear for 4th gear

23 -	Synchro-ring for 4th gear

q	Check for wear → Fig.

24 -	Locking collar with synchro-hub for 3rd and 4th gears

q	After removing retaining ring → Item, pull off via 4th gear synchromeshed gear → Item.

q	Dismantling → Fig.

q	Installation position, locking collar and synchro-hub → Fig.

q	Assembling locking collar and synchro-hub → Fig. and → Fig.

q	Pressing on → Fig.

25 -	Retaining ring

26 -	Synchro-ring for 3rd gear

q	Check for wear → Fig.

27 -	Outer ring for 3rd gear

q	Insert in synchro-ring → Item; installation position → Fig.

q	Renew if scored

28 -	Synchro-ring

q	(Inner ring for 3rd gear)

q	Check for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

29 -	Needle bearing

q	For 3rd gear

30 -	Synchromeshed gear for 3rd gear

q	Installation position → Fig.

31 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

32 -	Retaining ring

q	If tapered roller bearing → Item and output shaft → Item are renewed, redetermine → Fig.

33 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

34 -

Shim

q	Determining thickness → Chapter

35 -	Gearbox housing

Pulling dished washer -A- out of output shaft

Pressing dished washer into output shaft Dimension „a“ = 2 mm

Pulling out tapered roller bearing outer race A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 56…70 mm, e.g. -Kukko 21/8-

Pressing tapered roller bearing outer race into clutch housing –  Support clutch housing with drift sleeve -40-20- directly below bearing support.

Pulling off tapered roller bearing inner race –  First remove retaining ring. –  Before fitting puller, position press tool -VW 431- in output shaft and set thrust plate -V.A.G 40-105- on it.

Pulling off 3rd and 4th gear synchro-hub and locking collar over 4th gear synchromeshed gear –  First remove retaining ring. A -  Puller, e.g. -Kukko 18/2- B -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing off locking collar and synchro-hub for 1st and 2nd gears After removing retaining ring, press off synchromeshed gear for 2nd gear together with locking collar and synchro-hub.

Pressing off tapered roller bearing inner race A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing on tapered roller bearing inner race

Checking inner ring for 1st, 2nd and 3rd gears for wear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Gap „a“	Installation dimension	Wear limit
1st, 2nd and 3rd gears	0.75 ... 1.25 mm	0.3 mm

Checking synchro-rings for 1st, 2nd and 3rd gear for wear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation dimension	Wear limit
1st, 2nd and 3rd gears	1.2 ... 1.8 mm	0.5 mm

Installation position of outer ring, inner ring and synchro-ring for 2nd gear –  Place inner ring -A- on synchromeshed gear for 2nd gear. Angled lugs -arrows 1- face outer ring -B-. –  Fit outer ring -B-. Lugs -arrows 2- engage in notches -arrows 3- of synchromeshed gear. –  Fit synchro-ring -C-. Notches -arrows 4- engage in lugs -arrows 1- of inner ring -A-.

Dismantling and assembling locking collars and synchro-hubs of 1st and 2nd gears as well as 3rd and 4th gears 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.

Assembling locking collars and synchro-hubs for 1st and 2nd gears as well as 3rd and 4th gears Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Installation position of locking collar with synchro-hub for 1st and 2nd gears Identification groove -arrow 1- and narrow collar -arrow 2- of synchro-hub face 1st gear.

Pressing on locking collar and synchro-hub for 1st and 2nd gears –  Install retaining ring.

Installation position of outer ring for 1st or 3rd gear Lugs -arrows- face synchro-hub and locking collar -A-.

Installation position of synchro-ring -A- (inner ring for 1st or 3rd gear) Lugs -arrows 1- locate in notches -arrows 2- of synchro-ring -B-.

Installation position of synchromeshed gear for 1st and 3rd gears The higher collar -A- faces 2nd or 4th gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..

Installation position of locking collar with synchro-hub for 3rd and 4th gears Wider shoulder of synchro-hub -arrow- faces 3rd gear.

Pressing on synchro-hub with locking collar for 3rd and 4th gears –  Install retaining ring.

Checking synchro-ring for 4th gear for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Gap -a-	Installation dimension	Wear limit
4th gear	1.0 ... 1.7 mm	0.5 mm

Pressing on tapered roller bearing inner race –  Determine and install retaining ring → Fig..

Determining thickness of retaining ring –  Determine thickest retaining ring which will still fit and install it. –  Determine retaining ring from table. Part numbers → Electronic parts catalogue (ETKA). Available retaining rings

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	1.95

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46…58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Fit shim under outer race. –  Support gearbox housing with thrust piece -VAS 2050- below bearing support.