Volkswagen Workshop Service and Repair Manuals

Output shaft - dismantle and assemble

Special tools and workshop equipment required

t	Pressure pin -VW 407-

t	Pressure disc -VW 412-

t	Pressure disc -VW 512-

t	Puller -VAG 1582-

t	Clamp -VAG 1582/4-

t	Clamp -VAG 1582/5-

t	Plate -VW 402-

t	Placer -32-111-

t	Pressure pin -VW 408A-

t	Pressure pin -VW 409-

t	Placer -VW 457-

t	Tube -VW 519-

t	Pressure ring -VW 429-

t	Tube -VW 415A-

t	Pressure disc -VW 447 H-

t	Pressure tube -VW 454-

t	Installation collar -VW 455-

t	Installation collar -41-501-

t  Inner puller -Kukko 21/6- t  Counter-support -KUKKO 22/2-   Note t  The output shaft is disassembled the following way: - Place separation device underneath the gear wheel of the 2nd gear ( → Item) and remove it as described in → Fig. - Disassemble the safety ring ( → Item). - Remove locking collar of the 1st and 2nd gear as described in → Fig. t  When installing new gears or a new output shaft consult technical data → Chapter t  Both taper roller bearings must be renewed together as a set

1 -	Hexagon nut, 25 Nm + 90°

q	4 nuts for bearing support.

2 -	Clutch housing

3 -	Adjustment shim

q	For output shaft.

q	Adjustment overview → Chapter.

4 -	Small taper roller bearing outer race

q	Remove → Fig.

q	Install → Fig.

5 -	Small taper roller bearing inner race

q	Pull → Fig.

q	Install → Fig.

6 -	Output shaft

q	Is paired with final drive gear, always renew together as a set.

q	Adjust → Chapter.

7 -	Large taper roller bearing inner race

q	Remove → Fig.

q	Install → Fig.

8 -	Thrust washer

q	Place sealing rings (Qty. 4) on the bearing support bolts.

9 -	Bearing support

q	With large taper roller bearing outer race and bolts.

q	Only change outer race together with large taper roller bearing and bearing support.

10 -	Thrust washer

q	Shoulder on thrust washer faces taper roller bearing.

11 -	1st gear wheel

12 -	Needle roller bearing

q	For 1st gear.

13 -	Synchro ring

q	(1st gear inner race)

q	Installation position → Fig.

q	Check wear → Fig.

q	Check lugs for wear marks.

14 -	1st gear outer race

q	Installation position → Fig.

q	Check wear → Fig.

q	Renew if scorched or worn.

15 -	1st gear synchro-ring

q	Installation position → Fig.

q	Check wear → Fig.

16 -	Locking collar of the 1st and 2nd gears with synchrohub

q	Pull off with bearing support after removing the circlip ( → Item) → Fig.

q	Disassemble → Fig.

q	Assemble locking collar/synchro hub → Fig., → Fig. and → Fig.

q	Installation position → Fig.

q	Install → Fig.

17 -

Circlip

18 -	2nd gear synchro-ring

q	Check wear → Fig.

q	Assemble so that the recesses locate in the locking collar locking pieces ( → Item).

19 -	2nd gear outer race

q	Install in synchro ring ( → Item), installation position → Fig.

q	Renew if scorched or worn.

20 -	Synchro ring

q	(2nd gear inner ring)

q	Check wear → Fig.

q	Check lugs for wear marks.

q	Installation position → Fig.

21 -	2nd gear wheel

q	Installation position → Fig.

22 -	Needle roller bearing

q	for 2nd gear.

23 -	Thrust washer

24 -	Sleeve for 3rd. gear needle roller bearing

q	Remove with 2nd gear wheel → Fig.

q	Install → Fig.

25 -	Needle roller bearing

q	for 3nd gear

26 -	3rd gear wheel

27 -	3nd gear synchro-ring

q	Check wear → Fig.

28 -	Locking collar of the 3rd and 4th gears with synchrohub

q	Remove with the gears for the 2nd gear ( → Item) and for the 3rd gear ( → Item) → Fig.

q	Disassemble → Fig.

q	Assemble locking collar/synchro hub → Fig.

q	Installation position locking collar/synchro hub → Fig.

q	Install → Fig.

29 -

Bushing

q	For needle roller bearing.

q	Remove with the 3rd and 4th gear locking collar and synchro-hub ( → Item) → Fig.

q	Install → Fig.

30 -	Needle roller bearing

q	For 4th gear.

31 -	4th gear synchro-ring

q	Check wear → Fig.

32 -	4th gear wheel

33 -	Thrust washer

34 -	Needle roller bearing

q	For output shaft.

q	Remove and install → Fig.

35 -	Gearbox housing

36 -

Bushing

q	For output shaft needle roller bearing.

q	Remove → Fig.

q	Install → Fig.

37 -	5th gear wheel

q	Remove and install → Chapter.

38 -	Spring washer

q	Installation position .

39 -	M10 Torx screw, 80 Nm

q	Fitted portion on bolt head holds saucer spring washer in position.

Press out small taper roller bearing outer race A - Internal extractor 37 ... 1.81 in, e.g.-Kukko 21/6- B - Counter support, e.g. -Kukko 22/2-

Install small taper roller bearing outer race

Press out small taper roller bearing inner race A - Vice clamps/vice –  Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.

Install small taper roller bearing inner race

Remove synchro hub/locking collar of the 3rd and 4th gears, the gears of the 2nd, 3rd and 4th gear with the sleeves of the needle roller bearings of the output shaft A - Separating device 22 ... 4.53 in, e.g. -Kukko 17/2- B – Hexagon bolts M10×20   Note Support separating appliance so that the 1st. and 2nd. gear locking collar is not pulled off at the same time.

Pull off locking collar with synchrohub and bearing support –  First remove circlip -arrow-.

Press out big taper roller bearing inner race A - Protective jaws –  Before fitting puller insert a M10 x 20 hexagon bolt in the output shaft drilling.

Install big taper roller bearing inner race A - Thrust washer –  Fit thrust washer before pressing on the inner race. The shoulder points to the inner race.

Installation position of the outer race of the 1st gear wheel –  Place inner ring -A- on 1st. gear wheel. The angled lugs -arrows 1- point towards outer ring -B- –  Install outer ring -B- The lugs -arrow 2- engage in the selector gear recesses -arrow 3- –  Install synchro-ring-C- The recesses -arrow 4- fit on the lugs -1- of the inner ring -A-   Note If the components are not renewed, ensure they are reallocated to the original gear

Check 1st. and 2nd. gear inner race for wear –  Press inner ring onto cone of selector gear and measure gap “a” using a feeler gauge.

Dimension “a”	New dimension	Wear limit
1. and 2nd gear	0,75 ... 1.25 mm	0.3 mm

Check 1st and 2nd gear synchro ring for wear –  Press inner ring onto cone of selector gear and measure gap “a” using a feeler gauge.

Dimension “a”	New dimension	Wear limit
1st and 2nd gears	1,2 ... 1.8 mm	0.5 mm

Disassemble and assemble 1st and 2nd gear locking collar and synchro-hub 1 -  Spring Allocate circlip via Electronic Parts Catalogue Installation with hollow locking pieces → Fig. Installation with solid locking pieces → Fig. 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece Allocate locking pieces via Electronic Parts Catalogue The shoulder has the same width on both sides of synchro hub.   Note The shoulder has a chamfer on one side -arrow B- After assembly the shoulder of the synchro hub and the outer splines of the locking collar -arrow A- face same direction. Recesses for locking pieces on synchro hub and locking collar -arrow C- must align.

Assemble locking collar/synchro hub of the 1st and 2nd gears l  Locking collar is pushed over synchro hub. –  Insert locking pieces and install springs 120° offset. The angled end of the spring must locate in the hollow locking piece.

Assemble locking collar/synchro hub of the 1st and 2nd gears l  Locking collar is pushed over synchro hub. –  Insert locking pieces and install springs 120° offset. The angled end of the circlip must rest at the front of the locking pieces -arrows-.

Installation position of the locking collar/synchro hub of the 1st and 2nd gears The locking collar splines -arrow- point to splines for 3rd/4th gear synchrohub -A-.

Install locking collar/synchro hub of the 1st and 2nd gears Turn synchro ring so that the grooves align with the locking pieces.

Installation position of the outer race of the 2nd gear wheel The lugs -arrows- point towards the 1st gear -A-.

Installation position synchro ring (2nd gear inner ring) -A- The lugs -arrow 1- locate in the recesses -arrow 2- in the synchro-ring -B-

Installation position of the 2nd gear wheel The higher hub -A- faces the 1st gear -B-. The recesses in the collar -arrows- locate with the tabs of the outer ring arrow -arrow- → Fig.).

Pressing on needle roller bearing sleeve for 3rd gear

Check 3rd and 4th gear synchro ring for wear –  Press inner ring onto cone of selector gear and measure gap “a” using a feeler gauge.

Dimension “a”	New dimension	Wear limit
1. gear 3. gear 4. gear	1,0 ... 1,7 mm 1,0 ... 1,7 mm 1,0 ... 1,7 mm	0,5 mm

Disassemble and assemble 3rd and 4th gear locking collar and synchro-hub 1 -  Spring Allocate circlip via Electronic Parts Catalogue Install together with locking pieces → Fig. 2 -  locking piece Allocate locking pieces according to Electronic Parts Catalogue 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. The recesses for locking pieces in synchrohub and locking collar must align.

Assemble locking collar/synchro hub of the 3rd and 4th gears l  Locking collar is pushed over synchro hub. –  Insert locking pieces and install springs 120° offset. The angled end of the spring must locate in the hollow locking piece.

Assemble locking collar/synchro hub of the 3rd and 4th gears l  Locking collar is pushed over synchro hub. –  Insert locking pieces and install springs 120° offset. The angled end of the circlip must rest at the front of the locking pieces -arrows-.

Installation position of the locking collar/synchro hub of the 3rd and 4th gears Chamfer -arrow- points to 4th gear.

Install locking collar/synchro hub of the 3rd and 4th gears

Pressing on needle roller bearing sleeve for 4th gear

Press on sleeve for output shaft needle roller bearing