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Removing and installing reverse gear > < Disassembling and assembling secondary shaft (output shaft) up to 06.03

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Disassembling and assembling secondary shaft (output shaft) as of 06.03
Disassembling and assembling secondary shaft (output shaft) as of 06.03
Special tools and workshop equipment required
t  Inserting device for crankshaft gasket ring - T30070 (VW 204B)-
t  Pressure plate -MP3-406 (VW 401)-
t  Pressure plate -MP3-407 (VW 402)-
t  Thrust piece -MP3-408 (VW 412)-
t  Press-on sleeve -MP3-412 (VW 455)-
t  Multi-purpose tool -MP3-419 (VW 771)-
t  Thrust piece -MP3-423 (VW 407)-
t  Pipe section -MP3-429 (2010)-
t  Inserting device -MP3-436 (3128)-
t  Thrust piece -MP3-448 (VW 408A)-
t  Pipe section -MP3-450 (VW 415A)-
t  Pipe section -MP3-461 (VW 519)-
t  Pressure plate -MP3-472 (3118)-
t  Assembly device -MP5-402 (3301)-
t  Pipe section -MP3-4013 (VW 421)-
t  Thrust plate -T30045 (3005)-
t  Interior extractor 12...14.5 mm, e.g. - Kukko 21/1-
t  Separating device 22...115 mm, e.g. -Kukko 17/2-
   
  Note
t  As of gearbox manufacturing date 06.03, a new 3-pin synchronization for the 1st gear and a 2-pin synchronization for the 2nd gear as well as synchronizer rings with enlarged friction cone and reduced engaging gearing for 5th gear and reverse gear is used. The sliding gears, sliding sleeves and synchronizer bodies were adapted equivalently and cannot be fitted with synchronizer parts of old fitting status.
t  When installing new pinions or a drive shaft observe the technical data → Chapter and → Electronic Catalogue of Original Parts.
t  In case of replacement of the parts marked with 1) the adjustments need to be made. Setting overview → Chapter.
1 - Gearbox housing1)
q   is made out of aluminium or magnesium → Chapter
2 - Adjusting washer S3
q   Setting overview → Chapter
3 - Outer ring/taper roller bearing, large1)
q   removing → Fig.
q   installing → Fig.
4 - Secondary shaft (output shaft)1)
q   is paired with the crown wheel, replace together
q   Adjusting the secondary shaft and crown wheel → Chapter
5 - Inner ring/taper roller bearing, large1)
q   is damaged when removing
q   replace → Electronic Catalogue of Original Parts
q   pressing off → Fig.
q   pressing on → Fig.
6 - Circlip
q   mark
q   Fitting position → Fig., Pos. 1
q   if replacing the tapered-roller bearing, determine again → Fig.
7 - for 1st gear needle bearing
8 - 1st gear sliding gear
9 - Inner ring for 1st gear
q   Fitting position → Fig.
q   check for wear → Fig.
q   replace if there are any traces of scoring or of friction
10 - Intermediate ring for 1st gear
q   Fitting position → Fig.
q   check for wear → Fig.
11 - 1st gear synchronizer ring
q   Fitting position → Fig.
q   check for wear → Fig.
q   replace if there are any traces of scoring or of friction
12 - Sliding sleeve 1st and 2nd gear
q   Mark installation position
q   Assemble sliding sleeve and synchronizer body → Fig.
13 - Pressure plate
q   Install pressure plates (3 pieces) → Fig.
14 - Synchronizer body 1st and 2nd gear
q   pressing off → Fig.
q   high collar points to the 2nd gear
q   pressing on → Fig.
q   Assemble sliding sleeve and synchronizer body → Fig.
15 - Circlip
q   mark
q   Fitting position → Fig., Pos. 2
q   if replacing the synchronizer body, determine again → Fig.
16 - for 2nd gear needle bearing
17 - 2nd gear synchronizer ring
q   Fitting position → Fig.
q   check for wear → Fig.
q   replace if there are any traces of scoring or of friction
18 - Intermediate ring for 2nd gear
q   Fitting position → Fig.
q   check for wear → Fig.
19 - Inner ring for 2nd gear
q   Fitting position → Fig.
q   check for wear → Fig.
q   replace if there are any traces of scoring or of friction
20 - 2nd gear sliding gear
21 - Circlip
q   mark
q   Fitting position → Fig., Pos. 3
22 - 3rd gear pinion
q   pressing off → Fig.
q   Groove points to the 4th gear
q   pressing on → Fig.
23 - Circlip
q   mark
q   Fitting position → Fig., Pos. 4
q   if replacing the 3rd gear pinion, determine again → Fig.
24 - 4th gear pinion
q   pressing off → Fig.
q   Collar points to the 3rd gear
q   pressing on → Fig.
25 - Circlip
q   mark
q   Fitting position → Fig., Pos. 5
q   if replacing the 4th gear pinion, determine again → Fig.
26 - Needle bearing
27 - 5th gear sliding gear
q   Distinguishing feature → Fig.
28 - Spring
q   Modification feature → Fig.
q   place in the 5th gear sliding gear → Fig.
q   Assignment to sliding gear → Electronic Catalogue of Original Parts
29 - 5th gear synchronizer ring
q   Modification feature → Fig.
q   check for wear → Fig.
30 - Circlip
q   mark
q   Fitting position → Fig., Pos. 6
31 - 5th gear synchronizer body and reverse gear
q   Modification feature → Fig.
q   pressing off → Fig.
q   Collar points to the 5th gear sliding gear
q   pressing on → Fig.
32 - Circlip
q   mark
q   Fitting position → Fig., Pos. 5
q   if replacing the 5th gear synchronizer body and reverse gear, determine again → Fig.
33 - Needle bearing
q   for reverse gear
34 - Sliding sleeve for 5th gear and reverse gear
q   Modification feature → Fig.
q   Fitting position: groove points to the 5th gear sliding °gear → Fig.
35 - Reverse gear synchronizer ring
q   Modification feature → Fig.
q   check for wear → Fig.
36 - Spring
q   Modification feature → Fig.
q   position in the reverse gear sliding gear → Fig.
q   Assignment to sliding gear → Electronic Catalogue of Original Parts
37 - Reverse gear sliding gear
q   Modification feature → Fig.
38 - Inner ring/taper roller bearing, small1)
q   pressing off → Fig.
q   pressing on → Fig.
39 - Bush
q   for securing small outer ring/taper roller bearing
q   removing → Fig.
q   after replacing the small tapered-roller bearing it does no longer have to be installed
40 - Outer ring/taper roller bearing, small1)
q   removing → Fig.
q   installing → Fig.
41 - Adjusting washer S4
q   Setting overview → Chapter
42 - Pressure plate
q   different thickness for gearbox made out of aluminium and magnesium → Fig.
43 - Rubber washer
q   for linear compensation
q   to remove, drill a hole into the washer, screw in sheet metal screw and pull out at the sheet meet screw.
q   different thickness for gearbox made out of aluminium and magnesium → Fig.
q   Assign the components by gearbox code letters via the → electronic catalogue of original parts.
44 - Gearbox cover
q   made out of aluminium, must only be fitted with gearbox housing out of aluminium
q   made out of magnesium, must only be fitted with gearbox housing out of magnesium
q   Pay attention to the marking → Chapter
q   Thinly coat sealing surfaces with sealant -AMV 188 001 02-

   
Altered synchronization for 5th gear and reverse gear as of gearbox manufacturing date 06.03
  Note
Parts of existing fitting status up to gearbox manufacturing date 06.03 and parts of new fitting status as of gearbox manufacturing date 06.03 cannot be fitted together.
The following components were changed:
1 - 5th gear sliding gear
2 - Synchronizer spring
3 - 5th gear synchronizer ring
4 - 5th gear synchronizer body and reverse gear
5 - Sliding sleeve for 5th gear and reverse gear
6 - Reverse gear synchronizer ring
7 - Synchronizer spring
8 - Reverse gear sliding gear
Modification range:
t  reduced engaging gearing -arrows A-
t  Synchronizer rings with enlarged friction cone -arrows B-
  A35-0083
Remove the securing bush for small outer ring/tapered-roller bearing
A - Interior extractor 12...14.5 mm, e.g. -Kukko 21/1-
  S35-0214
Removing outer ring/tapered-roller bearing small
–  Screw adapter -MP3-419/40- into the pressure plate.
–  Screw in multi-purpose tool -MP3-419- and remove outer ring via the pressure plate.
  S35-0215
Pressing in small outer ring/tapered-roller bearing
  S35-0364
Removing large outer ring/tapered-roller bearing
–  Remove the differential gear → Chapter.
–  Place the pressure plate of the inserting device -MP3-436 - under the outer ring.
–  Mount the threaded spindle and pressure bearing of the assembly device -MP5-402- with pressure plate -MP3-406- onto the gearbox housing.
When tightening the nut -arrow- the outer ring is pulled out of the housing.
  S35-0224
Pressing on large outer ring/tapered-roller bearing
The small diameter of the inserting device - T30070- points to the outer ring.
  S35-0365
Press off small inner ring/tapered-roller bearing
–  Press off inner ring with reverse gear sliding gear.
A - Separating device 22...115 mm, e.g. -Kukko 17/2-
  S35-0217
Pressing off 5th gear synchronizer body and reverse gear
–  Remove circlip before pressing off.
–  Press off synchronizer body with 5th gear sliding gear.
A - Separating device 22...115 mm, e.g. -Kukko 17/2-
  S35-0219
Pressing out 4th gear pinion
–  Remove circlip before pressing off.
  S35-0220
Pressing out 3rd gear pinion
–  Remove circlip before pressing off.
  Note
When pressing off, make sure that only the teeth of the sliding gear -arrows- and not the engaging gearing rest on the separating device -A-. Otherwise the engaging gearing could be damaged.
–  Press off 3rd °gear pinion with 2nd gear sliding gear.
A - Separating device 22...115 mm, e.g. -Kukko 17/2-
  A35-0080
Pressing out synchronizer body for 1st and 2nd gear
–  Remove circlip before pressing off.
–  Press off synchronizer body with 1st gear sliding gear.
  S35-0222
Pressing off large inner ring/tapered-roller bearing
–  Remove circlip before pressing off.
–  To press off the inner ring, the outer ring -A- must be fitted on.
  S35-0223
Pressing on large inner ring/tapered-roller bearing
  S35-0226
Determining the circlip
–  Determine the thickest circlip - that can be fitted - and insert.
–  The circlips for the synchronizer body and gear pinions of the individual gears must be determined just as indicated for the ball bearing.
  V35-1173
Fitting position of circlips
  Note
Assign the circlips via the → Electronic catalogue of original parts.
t  Circlip -1- for inner ring/tapered-roller bearing.
  V35-1032
Circlip thickness (mm)
2,002,062,12
2,032,092,15

t  Circlip -2- for synchronizer body for 1st and 2nd gear.
Distinguishing feature: colour - blue
   
Circlip thickness (mm)
1,901,962,02
1,931,99 

t  Circlip -3- for the needle bearing/2nd gear sliding gear
Distinguishing feature: colour - blue
   
Circlip thickness (mm)
2,50

t  Circlip -4- for 3rd gear pinion.
   
Circlip thickness (mm)
1,901,982,06
1,942,02 

t  Circlip -5- for 4th gear pinion.
   
Circlip thickness (mm)
1,861,94 
1,901,98 

t  Circlip -6- for the needle bearing/5th gear sliding gear
Distinguishing feature: colour - brown
   
Circlip thickness (mm)
2,00

t  Circlip -7- for synchronizer body for 5th gear and reverse gear.
Distinguishing feature: colour - blue
   
Circlip thickness (mm)
1,901,962,02
1,931,992,05

   
Fitting position of the 1st and 2nd gear synchronizer rings.
  Note
If the components are not replaced, assign the original gear again.
–  Position inner ring -2- on sliding gear -1-.
–  Position intermediate ring -3-. The peg -B- must lock in the recess -A-.
–  Fit on synchronizer ring -4-. Guide the pegs -C- through the recess -arrow-.
  A35-0086
Check 1st gear inner ring for wear
–  Inspect outer contact surfaces -Pfeil- for traces of scoring and friction, if necessary replace.
–  Press the inner ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.
  A35-0095
Clearance “a”Installed size newWear limit
1st °gear - Inner ring1.2…2.0 mm0.6 mm

   
Check 1st and 2nd gear snychronizer ring for wear
–  Inspect synchronizer ring on the inner friction surface for traces of scoring or friction, replace if necessary.
–  Press the inner ring, intermediate ring and synchronizer ring on the cone of the sliding gear and measure clearance -a- with a feeler gauge.
  A35-0087
Clearance “a”Installed size newWear limit
1. and 2nd gear1.4…2.0 mm0.8 mm

   
Press on synchronizer body for 1st and 2nd gear
Fitting position: High collar points to the 2nd gear.
–  Position the pipe section -VW 415A (MP3-450)- with the shoulder pointing to the synchronizer body. Then position the pipe section -VW 519 (MP3-461)- and press on the synchronizer body using the pressure spindle -VW 412 (MP3-408)- up to the stop.
  A35-0084
Assembling the sliding sleeve and 1st and 2nd gear synchronizer body
–  Insert the pressure pieces -arrows A- into the installed synchronizer body -1-.
–  Fit the sliding sleeve -2- over the synchronizer body in such a way that the wide interrupted spacing of the sliding sleeve is aligned with the synchronizer body -arrow B-.
  A35-0082
Pressing on 3rd gear pinion
Fitting position: The groove on the gear pinion points to the 4th gear.
  S35-0228
Pressing on 4th gear pinion
Fitting position: High collar points to the 3rd gear.
  S35-0229
Insert spring in sliding gear
The looped spring end -arrow- must engage in the hole in the sliding gear.
  V35-1036
Checking 5th gear or reverse gear synchronizer ring for wear
–  Press synchronizer ring into sliding sleeve and measure the size of gap -a- with a feeler gauge in positions -A-, -B- and -C-.
–  Add up the measurements and divide by 3.
The resulting value should not be less than 0.5 mm.
  V35-1342
Pressing on 5th gear synchronizer body and reverse gear
Fitting position: High collar points to the 5th gear.
The large inner diameter in the pipe section -MP 3-429- points to the synschronizer body.
  S35-0230
Fitting position of 5th gear and reverse gear sliding sleeve
t  Fitting position:
Groove -arrow- points towards the reverse gear.
The sliding sleeve is symmetrical.
It can also be installed in such a way that the groove points to the 5th °gear.
  A35-0088
Press on small inner ring/tapered-roller bearing
  S35-0218
Difference between pressure plates
  N35-0061
 Dimension -a-
for gearbox made out of aluminium14.8 mm or
15.3 mm
for gearbox made out of magnesium10.7 mm

   
Difference between the rubber washers
  N35-0062
 Dimension -a-
for gearbox made out of aluminium7 mm
for gearbox made out of magnesium11 mm

   

Removing and installing reverse gear > < Disassembling and assembling secondary shaft (output shaft) up to 06.03