Volkswagen Workshop Service and Repair Manuals

Assembly overview - output shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust pad -VW 512-

t	Puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	Adapter -V.A.G 1582/5-

t	Pressure plate -VW 402-

t	Thrust piece -32 - 111-

t	Press tool -VW 408 A-

t	Press tool -VW 409-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Thrust ring -VW 429-

t	Tube -VW 415 A-

t	Thrust pad -VW 447 H-

t	Thrust piece -VW 454-

t	Installing sleeve -VW 455-

t	Drift sleeve - 41 - 501-

t  Internal puller -1 - Kukko 21/6- t  Counter support -4 - Kukko 22/2-

t  Two-arm puller -1 - Kukko 20/10- with 250 mm long hooks t  Hexagon bolt M10 x 20   Note The output shaft is dismantled as follows: - Position separating device under 2nd gear synchromeshed gear → Item and press off as shown in Fig. → Fig.. - Remove retaining ring → Item. - Position two-arm puller under bearing support → Item and pull off locking collar with 1st and 2nd gear synchro-hub as shown in Fig. → Fig..   Note t  When installing new gear wheels or a new output shaft, consult technical data → Chapter. t  If the position of the tapered roller bearings is affected when parts are exchanged, the output shaft must be readjusted. See adjustment overview → Chapter. t  Always renew both tapered roller bearings together as a set. t  Removing and installing output shaft → Chapter.

1 -	Hexagon nut

q

→ Item

2 -	Clutch housing

3 -

Shim

q	Determining thickness → Chapter

4 -	Small tapered roller bearing outer race

q	Removing → Fig.

q	Pressing in → Fig.

5 -	Small tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

6 -	Output shaft

q	Paired with final drive gear wheel. Always renew as a set.

q	Adjusting → Chapter

7 -	Large tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

8 -

Seal

q	Always renew

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

9 -	Bearing support

q	With large tapered roller bearing outer race and bolts

q	Change outer race only together with large tapered roller bearing and bearing support

10 -	Thrust washer

q	Shoulder of thrust washer faces tapered roller bearing

11 -	Synchromeshed gear for 1st gear

q	From gearbox date 04 09 0 onwards, 1st gear synchronisation was changed → Chapter

12 -	Needle bearing

q	For 1st gear

13 -	Synchro-ring for 1st gear

q	Check for wear → Fig.

q	Identification → Fig.

q	Distinguishing → Fig.

q	From gearbox date 04 09 0 onwards, 1st gear synchronisation was changed → Chapter

14 -	Locking collar with synchro-hub for 1st and 2nd gears

q	After removing retaining ring → Item, pull off via bearing support → Fig.

q	Dismantling → Fig.

q	Assembling locking collar and synchro-hub → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

q	From gearbox date 04 09 0 onwards, 1st gear synchronisation was changed → Chapter

15 -	Retaining ring

16 -	Synchro-ring for 2nd gear

q	Identification → Fig.

q	Distinguishing → Fig.

q	Check for wear → Fig.

q	Assemble so that notches engage in locking pieces of locking collar → Item

17 -	Outer ring

q	Insert in synchro-ring → Item; installation position → Fig.

q	Renew if scored

18 -	Synchro-ring

q	(Inner ring)

q	Check for wear → Fig.

q	Check lugs for scoring

q	Installation position → Fig.

19 -	Synchromeshed gear for 2nd gear

q	Installation position → Fig.

20 -	Needle bearing

q	For 2nd gear

21 -	Thrust washer

22 -	Sleeve for 3rd gear needle bearing.

q	Pressing off with synchromeshed gear for 2nd gear → Fig.

q	Pressing on → Fig.

23 -	Needle bearing

q	For 3rd gear

24 -	Synchromeshed gear for 3rd gear

25 -	Synchro-ring for 3rd gear

q	Check for wear → Fig.

26 -	Locking collar with synchro-hub for 3rd and 4th gears

q	Press off with 2nd gear synchromeshed gear → Item and 3rd gear → Item → Fig..

q	Dismantling → Fig.

q	Installation position, locking collar and synchro-hub → Fig.

q	Assembling locking collar and synchro-hub → Fig.

q	Pressing on → Fig.

27 -

Sleeve

q	For needle bearing

q	Press off with locking collar and synchro-hub for 3rd and 4th gears → Item

q	Pressing on → Fig.

28 -	Needle bearing

q	For 4th gear

29 -	Synchro-ring for 4th gear

q	Check for wear → Fig.

30 -	Synchromeshed gear for 4th gear

31 -	Thrust washer

32 -	Needle bearing

q	For output shaft

q	Removing and installing → Chapter

33 -	Gearbox housing

34 -

Sleeve

q	For output shaft needle roller bearing

q	Pressing off → Fig.

q	Pressing on → Fig.

35 -	Gear wheel for 5th gear

q	Removing and installing → Chapter

36 -	Dished washer

q	Installation position → Anchor

37 -	Torx socket head bolt M10

q

→ Item

Pulling out small tapered roller bearing outer race -A-Internal puller 37 ... 46 mm -Kukko 21/6- -B-Counter support -Kukko 22/2-

Pressing in small tapered roller bearing outer race

Pulling off small tapered roller bearing inner race -A- Vice with jaw protectors –  Fit adapter and tighten behind bearing rollers, then turn bearing and retighten gripping device.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with gearbox housing needle roller bearing sleeve -A-Splitter 22 … 115 mm -Kukko 17/2- -B- 17 mm hexagon bolt, 10 x 20 mm   Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.

Pulling off locking collar with synchro-hub via bearing support -A-Two-arm puller -Kukko 20/10- with 250 mm long hooks -B- 17 mm hexagon bolt, 10 x 20 mm   Note Remove circlip before pulling off individual components.

Pulling off large tapered roller bearing inner race -A- Vice jaw protectors –  Before fitting puller, insert a M10 x 20 hexagon bolt in output shaft drilling.

Pressing on large tapered roller bearing inner race -A- Thrust washer –  Fit thrust washer before pressing on inner race. Shoulder faces inner race.

Checking synchro-ring for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap “a” using feeler gauge.

Gap “a”	Installation (new) dimension	Wear limit
1st gear 3rd gear 4th gear	1.0 ... 1.7 mm 1.0 … 1.7 mm 1.0 … 1.7 mm	0.5 mm

Identifying 1st and 2nd gear synchro-rings t  1st gear synchro-ring - 3 ground-down half teeth-arrow- t  2nd gear synchro-ring - 3 half teeth-arrow- or 2 ground-down half teeth Only the version with “2 ground-down half teeth” is available as a replacement part for the 2nd gear synchro-ring.

Distinguishing 1st and 2nd gear synchro-rings t  1st gear synchro-ring - no recesses t  2nd gear synchro-ring - three recesses -arrows-

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. The wide shoulder of the synchro-hub -arrow A- and the outer splines of the locking collar -arrow B- face opposite directions after assembly. Recesses for locking pieces on synchro-hub and 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 and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

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

Pressing on locking collar and synchro-hub for 1st and 2nd gears   Note Before pressing on, place 1st gear synchro-ring on 1st gear wheel.

Checking 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 (new) dimension	Wear limit
2nd gear	1.2 ... 1.8 mm	0.5 mm

Installation position outer-ring Lugs -arrows- face 1st gear -A-.

Checking inner ring for wear –  Press inner ring onto cone of 2nd gear synchromeshed gear and measure gap “a” with a feeler gauge.

Gap “a”	Installation (new) dimension	Wear limit
2nd gear	0.75 ... 1.25 mm	0.3 mm

Installation position synchro-ring (inner-ring) -A- Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

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

Pressing on sleeve for 3rd gear needle bearing

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.

Assembling locking collar and synchro-hub for 3rd and 4th gears Locking collar has been pushed over synchro-hub. Locking pieces are hollow on inside. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece. Locking pieces are not hollow on inside. –  Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces.

Installation position of locking collar with synchro-hub for 3rd and 4th gears Chamfer -arrow- faces 4th gear.

Pressing on synchro-hub with locking collar for 3rd and 4th gears

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for output shaft needle bearing