Volkswagen Workshop Service and Repair Manuals

Assembling output shaft 2 In this procedure, you will see how output shaft 2 is assembled. Make sure that shaft bearing is not damaged during following work on press. If bearing is not going to be renewed then it must be protected. l  If bearing is pressed on, thrust plate -VW 447 H- must also be used for each pressing operation. l  Pressing off bearing: → Anchor l  Pressing on bearing: → Anchor

–  Place both needle bearings onto output shaft. –  Make sure that cages are not broken. –  Wet bearing with oil. –  Fit reverse gear wheel.

–  Put on reverse gear wheel, axial bearing »with smooth side facing upwards«. –  Put on locking collar with synchro-hub. Make sure circumferential edge of sleeve is pointing »upwards«, and collar of locking collar »downwards«. Dismantling and assembling locking collar → Chapter. Synchro-hub can only be put in place. It is pressed on in next step.

–  Press on synchro-hub.   Note Stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing!

–  Press on sleeve for synchromeshed gear for 6th gear.

–  Put on synchro-ring, needle bearing and synchromeshed gear for 6th gear. –  Wet bearing and friction surfaces with oil.

–  Press on washer for synchromeshed gear for 6th gear. If this washer has lettering then position this side of washer »downwards«.   Note t  Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing! t  After pressing, gear wheel must turn »freely« when shaft is in horizontal position. t  Output shaft is assembled as far as this washer for purpose of adjusting shaft.

Do not assemble output shaft further until gearbox has been adjusted.

–  Press on sleeve for needle bearing of synchromeshed gear for 7th gear.   Note Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing!

–  Put on needle bearing, synchromeshed gear for 7th gear and synchro-ring. –  Wet bearing and friction surface with oil. –  Put on locking collar with synchro-hub. Make sure circumferential edge of sleeve is pointing »upwards«, and collar of locking collar »downwards«. Synchro-hub can only be put in place. It is pressed on in next step.

–  Press on synchro-hub.   Note t  Bear two things in mind when pressing: t  Raise gear wheel and turn it at same time. This allows synchro-ring to locate its installation position before ring is clamped by synchro-hub. t  Once ring has located its seat, pay attention to force required for pressing. Stop pressing as soon as you feel a stop (increased force requirement). Synchromeshed gear for 3rd gear must have axial play. Gear has reached its installation position as soon as force during pressing rises. If you continue pressing then you will be pressing synchro-hub against needle bearing, thus damaging it. t  After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on sleeve for needle bearing of synchromeshed gear for 5th gear.   Note Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing!

–  Put on synchro-ring, needle bearing and gear wheel for 5th gear. –  Wet bearing and friction surface with oil.

–  Press on bearing. –  Wet bearing with oil.

–  Tighten new bolt. Torque settings: 60 Nm, 90° further. Special wrench -T10035- can also be used for tightening.