Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 5th, 6th and reverse 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 408A-

t	Press tool -VW 412-

t	Tube -VW 415A-

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Support rail -VW 457-

t	Support plate -VW 801-

t	Thrust piece -VW 431-

t	Installing sleeve -VW 455-

t	Thrust pad -VW 510-

t	Tube -VW 516-

t	Tube -VW 519-

t	Thrust plate -30-11-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Thrust piece -2050-

t	Tube -3296-

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

t	Adapter -V.A.G 1582/4-

t  Adapter -V.A.G 1582/7-

t  Internal puller -1 - Kukko 21/7- t  Splitter -3 - Kukko 17/2- t  Counter support -4 - Kukko 22/2-

Pull off tapered roller bearing inner race on side facing clutch housing –  Before setting up pulling device, set thrust plate -30-11- on output shaft.

Press on tapered roller bearing inner race on side facing clutch housing

Pulling tapered roller bearing outer race out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46 … 58 mm, e.g. -Kukko 21/7-   Note After pulling out, check washer for damage and renew if necessary.

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

Pull off tapered roller bearing inner race on side facing gearbox housing Before setting up tapered roller bearing puller: –  Remove retaining ring for tapered roller bearing inner race on side facing gearbox housing. –  Place press tool -VW 431- and thrust plate -40-105- onto output shaft.

Press on tapered roller bearing inner race on side facing gearbox housing –  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 number → Electronic parts catalogue (ETKA) Available retaining rings

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	195

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 –  Support gearbox housing with thrust piece -2050- below bearing support. Dismantle output shaft.   Note Pull off tapered roller bearing inner race on side facing gearbox housing → Fig..

Pressing off synchro-hub and locking collar for 5th and 6th gears with synchromeshed gear for 6th gear –  First remove retaining ring.

Pressing off sleeve -A- with reverse gear synchromeshed gear. –  First remove retaining ring.

Pressing off reverse gear synchro-hub –  First remove retaining ring. A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2- Assembling output shaft.

Installation position of reverse gear synchro-hub Stop of reverse gear locking collar -arrow A- faces teeth of output shaft -arrow B-.

Pressing on reverse gear synchro-hub –  Install retaining ring. –  Place reverse gear locking collar on reverse gear synchro-hub. –  Put on reverse gear synchromeshed gear with needle bearing.

Pressing on sleeve -A- Installation position: Wide collar faces reverse gear synchromeshed gear. –  Install retaining ring.

Checking synchro-rings for 5th and 6th gear for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Gap -a-	Installation dimension	Wear limit
5. and 6th gear	1.0 … 1.7 mm	0.5 mm

Dismantling and assembling locking collar and synchro-hub for 5th and 6th 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 collar with synchro-hub for 5th and 6th 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. –  Install 6th gear synchromeshed gear with needle bearing. –  Put on synchro-ring for 6th gear.

Pressing on locking collar and synchro-hub for 5th and 6th gears Some locking collars have a chamfer on their outer diameter. Installation position: The chamfer on the outer diameter of the sliding sleeve points towards the 5th gear synchromeshed gear. –  Turn synchro-ring so that grooves align with locking pieces. –  Install retaining ring. –  Put on synchro-ring for 5th gear. –  Install 5th gear synchromeshed gear with needle bearing.   Note t  Press on tapered roller bearing inner race on side facing gearbox housing → Fig.. t  Determine retaining ring for tapered roller bearing inner race → Fig..