Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Pressure plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Thrust piece -VW 432-

t	Drift sleeve -30 - 100-

t  -1-Internal puller -Kukko 21/5- t  -4-Counter support -Kukko 22/1-

Pulling cylindrical roller bearing out of clutch housing –  When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-. A -  Counter support, e.g. -Kukko 22/1- B -  Internal puller, 30 … 37 mm, e.g. -Kukko 21/5-

Pressing cylindrical roller bearing into clutch housing –  Support gearbox housing with tube -VW 415 A- (not visible here) directly below bearing support. –  When pressing in, squeeze together retaining ring -arrow- for cylindrical roller bearing using pliers -A-. –  Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing. Dismantling output shaft When 5th gear wheel -A- cannot be removed by hand.

Pressing off bearing mounting with deep groove ball bearing and gear wheel for 5th gear -A- –  Slide locking collar for 1st and 2nd gear towards 2nd gear. –  Then slide pressure plate -T10084 A- onto input shaft to stop from side. When 5th gear wheel can be removed by hand.

Pressing off bearing mounting with deep groove ball bearing. –  Slide locking collar for 1st and 2nd gear towards 2nd gear. –  Then slide pressure plate -T10084 A- onto input shaft to stop from side.

Pressing retaining ring -1- out of groove A -  Protective gloves   WARNING Ensure retaining ring does not spring out uncontrolled.

Pressing off 1st and 2nd gear locking collar and synchro-hub –  Before pressing off, remove retaining ring for synchromeshed gear for 2nd gear.

–  Remove retaining ring -1- and remove gear wheel for 3rd gear -B- by hand. –  Remove retaining rings -2- and -3- and remove gear wheel for 4th gear -A- by hand. Assembling output shaft.

Installation position of 3rd gear and 4th gear –  Install gear wheel for 4th gear -A- on output shaft. Installation position: Collar -arrow 1- faces 3rd gear wheel -B-. –  Install retaining rings -2- and -3-. –  Install gear wheel for 3rd gear -B- on output shaft. Installation position: Collar -arrow 2- faces gear wheel for 4th gear -A-. –  Install retaining ring -1-.

Checking 1st and 2nd gear inner ring 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 and 2nd gears	0.75 … 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-rings 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 and 2nd 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 -arrow 1- face outer ring -B-. –  Fit outer ring -B-. Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear. –  Fit synchro-ring -C-. Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.

Dismantling and assembling locking collar and synchro-hub for 1st and 2nd gears 1 -  Spring 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece –  Slide locking collar over synchro-hub. Installation position: After assembly, the groove on the face -arrow A- and the higher shoulder -arrow B- of synchro-hub face outer splines of the locking collar -arrow C-. Deeper notches -arrow D- for locking pieces in synchro-hub and notches -arrow E- in locking collar must align.

Assembling locking collar with synchro-hub for 1st and 2nd gears l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces in deeper cut-outs -arrows- and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Pressing on locking collar and synchro-hub for 1st and 2nd gears Installation position: Groove in locking collar for selector fork faces 1st gear and teeth for reverse gear face 2nd gear. –  Turn synchro-ring so that grooves align with locking pieces.

Fitting retaining ring –  Place 1st gear synchro-ring in locking collar/synchro-hub.

Installation position of 1st gear outer ring Lugs -arrows- face towards reverse gear teeth.

Installation position of 1st gear inner ring -A- Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

Installation position of synchromeshed gear for 1st gear Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..

Pressing on bearing mounting with deep groove ball bearing. –  Heat inner bearing mounting to approx. 100 °C before pressing on.