Volkswagen Workshop Service and Repair Manuals

Assembling output shaft 1 In this procedure, you will see how output shaft 1 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 i- must also be used for each pressing operation. l  Pressing off bearing: → Anchor l  Pressing on bearing: → Anchor

–  Place needle bearing onto output shaft. –  Make sure that cage is not broken. –  Wet bearing with oil.

–  Place synchromeshed gear for 2nd gear onto needle cage. –  Wet friction surfaces with oil. –  Place both synchro-rings with outer ring on gear wheel for 2nd gear. –  Put on locking collar with synchro-hub. Make sure groove for selector fork 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 2nd 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. After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on sleeve for needle bearing of synchromeshed gear for 4th gear. Installation direction: lettering points »downwards«.   Note Here too, stop pressing immediately when you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing with oil. –  Wet friction surfaces with oil. –  Put on large synchro-ring, outer ring and small synchro-ring.

–  Put on synchromeshed gear for 4th gear.

–  Press on washer.   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 3rd gear.   Note Here too, stop pressing immediately when sleeve has located its position and you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing and friction surfaces with oil. –  Put on synchromeshed gear for 3rd gear, small synchro-ring, outer ring and large synchro-ring.

–  Press on locking collar and 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. After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on sleeve for needle bearing of synchromeshed gear for 1st gear.   Note Here too, stop pressing immediately when sleeve has located its position and you notice a rise in force during pressing. Do not continue pressing!

–  Fit needle bearing. –  Wet bearing and friction surfaces with oil. –  First place small synchro-ring onto synchromeshed gear for 1st gear. –  Then outer ring and then large synchro-ring. Gear wheel and rings can be placed on shaft together.

–  Press on washer.   Note Here too, stop pressing immediately when washer has located its position and you notice a rise in force during pressing. Do not continue pressing! After pressing, gear wheel must turn »freely« when shaft is in horizontal position.

–  Press on bearing.   Note Here too, stop pressing immediately when bearing has located its position and you notice a rise in force during pressing. Do not continue pressing! –  Wet bearing with oil.

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