Power transmissionDrive shaft
| Disassembling and assembling the drive shaft |
| Special tools and workshop equipment required |
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| Pressure plate -MP3-406 (VW 401)- |
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| Thrust piece -MP3-408 (VW 412)- |
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| Pipe section -MP3-461 (VW 519)- |
Note | When installing new pinions or drive shaft observe the technical data → Chapter. |
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| identify before removing |
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| not to be confused with needle bearing for 3rd gear |
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| lubricate with gear oil before installing |
| 7 - | 4th gear sliding gear |
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| place in the 4th gear sliding gear Pos. 7 → Fig. |
| 9 - | 4th gear synchronizer ring |
| 10 - | Sliding sleeve 3rd and 4th gear |
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| is paired with synchronizer body Pos. 12 |
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| If replacing the synchronizer body Pos. 12, determine thickness of circlip again → Fig. |
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| Fitting position: ends in line with groove in synchronizer body |
| 12 - | Synchronizer body for 3rd and 4th gear |
| 13 - | 3rd gear synchronizer ring |
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| insert in the 3rd gear sliding gear Pos. 15 → Fig. |
| 15 - | 3rd gear sliding gear |
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| identify before removing |
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| not to be confused with needle bearing for 4th gear |
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| lubricate with gear oil before installing |
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| insert when replacing the drive shaft → Fig. |
| 19 - | Cylindrical-roller bearing |
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| for cylindrical-roller bearing |
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| position/remove manually |
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| for needle bearing for 6th gear sliding gear |
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| Fitting position: Collar for circlip, smooth thrust surface for needle bearing → Chapter |
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| lubricate with gear oil before installing |
| 25 - | 6th gear sliding gear |
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| after installing, check axial play with feeler gauge (0.15...0.35 mm) |
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| insert in the 6th gear sliding gear Pos. 25 → Fig. |
| 27 - | 6th gear synchronizer ring |
| 28 - | Synchronizer body for 5th and 6th gear |
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| Fitting position: projecting hub towards 5th gear sliding gear |
| 29 - | Sliding sleeve 5th and 6th gear |
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| is paired with synchronizer body Pos. 28 |
| 30 - | 5th gear synchronizer ring |
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| insert in the 5th gear sliding gear Pos. 32 → Fig. |
| 32 - | 5th gear sliding gear |
| 33 - | Inner ring for needle bearing |
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| for 5th gear sliding gear |
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| lubricate with gear oil before installing |
| 35 - | 1st Inner ring for four-point bearing |
| 37 - | 2nd inner ring for four-point bearing |
| Insert spring in sliding gear |
| The looped end of the spring -arrow- must engage in the hole in the sliding gear. |
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| Check synchronizer ring for wear |
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| Press synchronizer ring into sliding sleeve and measure the size of gap -a- with a feeler gauge at positions -A-, -B- and -C-. |
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| Add up the measurements and divide by 3. |
| The resulting value should not be less than 0.5 mm. |
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| Synchronizer body pressed up to the stop. |
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| Determine the thickest circlip - that can be fitted - and insert. |
Note | The following circlips are available: |
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| Circlip thickness (mm) |
| 1,90 | 1,96 | 2,02 |
| 1,93 | 1,99 | 2,05 |
| Press off synchronizer body for 3rd and 4th gear |
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| Fitting position of synchronizer body |
| Oil groove in synchronizer body -arrow 1- must be in line with the oil drilling -arrow 2- in the drive shaft. |
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| Press on synchronizer body for 3rd and 4th gear |
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| Heat synchronizer body to approx. 100 °C, place in position and press on. |
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| Determine the circlip required, and mount it → Fig.. |
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| Drive tensioning sleeve into drive shaft |
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| Insert -A- Ø 9 mm drift pin into oil drilling and drive in tensioning sleeve -B- till it meets the drift pin. |
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06 Transmission
