Power transmissionSecondary shaft (output shaft)
| Disassembling and assembling the secondary shaft |
| Special tools and workshop equipment required |
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| Drive bushing -MP1-316 (30-100)- |
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| Drift -MP3-403 (VW 295)- |
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| Pressure plate -MP3-406 (VW 401)- |
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| Thrust piece -MP3-408 (VW 412)- |
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| Multi-purpose tool -MP3-419 (VW 771)- |
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| Drive bushing -MP3-427 (40-21)- |
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| Pipe section -MP3-429 (2010)- |
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| Thrust piece -MP3-448 (VW 408A)- |
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| Pipe section -MP3-461 (VW 519)- |
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| Thrust piece -MP6-405 (VW 411)- |
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| Drawing ring -T30036/3 (2003/3)- |
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| Thrust plate -T30045 (3005)- |
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| Pressure washer -T30047 (3062)- |
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| Guide bushing -T30075 (3039)- |
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| Separating device 22...115 mm, e.g. -Kukko 17/2- |
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Note
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| When installing new pinions or drive shaft observe the technical data → Chapter. |
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| In case of replacement of the parts marked with 1) the adjustments need to be made. Setting overview → Chapter. |
| 3 - | Outer ring/taper roller bearing, large1) |
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| is paired with the crown wheel - if replacing, replace both |
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| Adjusting the secondary shaft and crown wheel → Chapter |
| 5 - | Inner ring/taper roller bearing, large1) |
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| press off together with inner ring Pos. 9 → Fig. |
| 9 - | Inner ring for needle bearing |
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| for 2nd gear sliding gear |
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| press off together with 3rd gear pinion Pos. 8 → Fig. |
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| for 2nd gear sliding gear |
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| lubricate with gear oil before installing |
| 11 - | 2nd gear sliding gear |
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| before installing, insert spring Pos. 12 and push needle bearing Pos. 10 onto secondary shaft |
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| insert in the 2nd gear sliding gear Pos. 11 → Fig. |
| 13 - | 2nd gear synchronizer ring |
| 14 - | Synchronizer body for 1st and 2nd gear |
| 15 - | Sliding sleeve for 1st and 2nd gear |
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| Fitting position: groove for selector rod facing towards 1st gear sliding gear Pos. 20 |
| 16 - | Inner ring for needle bearing |
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| for 1st gear sliding gear |
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| for 1st gear sliding gear |
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| lubricate with gear oil before installing |
| 18 - | 1st gear synchronizer ring |
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| insert in the 1st gear sliding gear Pos. 20 → Fig. |
| 20 - | 1st gear sliding gear |
| 21 - | Inner ring/taper roller bearing, small1) |
| 23 - | Outer ring/taper roller bearing, small1) |
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| Fitting position: collar points towards inner ring/tapered-roller bearing small |
| Removing large outer ring/tapered-roller bearing |
| Thrust washer -T30047 (3062)- lies with the graduated side on the outer ring. |
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| Inserting the large outer ring/tapered-roller bearing into the gearbox housing and pressing down |
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| Heat the gearbox housing with the hot-air blower in the area of the bearing assembly, to about 100°C for around 15 minutes. |
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| Insert the outer ring in the heated gearbox, and press in under the workshop press until heat is transferred. |
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| Pressing off the small inner ring/taper roller bearing with 1st gear sliding gear |
| A - | Separating device 22...115 mm, e.g. -Kukko 17/2- |
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| Pressing off 2nd gear sliding gear with sliding sleeve/synchronizer body for 1st and 2nd gear and inner ring for needle bearing/1st gear sliding gear |
| A - | Separating device 22...115 mm, e.g. -Kukko 17/2- |
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| Pressing off 3rd gear pinion with inner ring for needle bearing/2nd gear sliding gear |
| A - | Separating device 22...115 mm, e.g. -Kukko 17/2- |
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| Pressing out 4th gear pinion |
| A - | Separating device 22...115 mm, e.g. -Kukko 17/2- |
Note | The 4th gear pinion can also be pressed off together with 3rd gear pinion and inner ring for needle bearing/3rd gear sliding gear |
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| Pressing off large inner ring/tapered-roller bearing |
| A - | Separating device 22...115 mm, e.g. -Kukko 17/2- |
| The bearing is destroyed by removing |
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| Pressing on large inner ring/tapered-roller bearing |
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| Heat inner ring to around 100 °C and mount. |
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| Press down till there is no axial play. |
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| Pressing on 4th gear pinion |
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| Heat pinion to around 100 °C, place in position and press on. |
| Collar towards 3rd gear pinion. |
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| Pressing on 3rd gear pinion |
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| Mount spacer sleeve -arrow-. |
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| Heat 3rd gear pinion to approx. 100 °C, mount, and press down. |
| Collar towards 4th gear pinion. |
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| Pressing on inner ring -A- for needle lager/ 2nd gear sliding gear |
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| Heat inner ring to around 100 °C and mount. |
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| Press down till there is no axial play. |
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| 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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| Mounting 2nd gear sliding gear, pressing on 1st and 2nd gear synchronizer body |
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| Lubricate needle bearing. |
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| Mount the needle bearing, sliding gear with spring, and synchronizer ring for 2nd gear. |
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| Heat inner synchronizer body to around 100 °C and mount. |
| Level hub with 2nd gear sliding gear. |
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| Press down till there is no axial play. |
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| Mount sliding sleeve for 1st and 2nd gear. |
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| Pressing on inner ring -A- for needle bearing/ 1st gear sliding gear |
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| Heat inner ring to around 100 °C and mount. |
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| Press down till there is no axial play. |
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| Press on small inner ring/tapered-roller bearing |
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| Lubricate needle bearing. |
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| Mount the needle bearing, sliding gear with spring, and synchronizer ring for 1st gear. |
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| Heat inner ring to around 100 °C and mount. |
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| Press down till there is no axial play. |
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| Extracting small outer ring/tapered-roller bearing |
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| Pressing in small outer ring/tapered-roller bearing |
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| Place washer S4 in the bearing pedestal in the bearing bracket. |
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| Press in outer ring for small tapered-roller bearing till it reaches the stop. |
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06 Transmission
