Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ VW 407 Press tool
• ◆ VW 447 H Press plate
• ◆ VW 412 Press tool
• ◆ VW 422 Tube
• ◆ VW 401 Thrust plate
• ◆ VW 408 A Press tool

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ VW 421 Tube
• ◆ VW 454 Press piece
• ◆ VW 447 i Thrust plate
• ◆ VW 510 Press piece
• ◆ 41-501 Drift sleeve
• ◆ 3 - Kukko 17/1 Separating device

Notes:

• ◆ When installing new gears, consult technical data
  .
• ◆ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview

• Clutch housing
• Taper roller bearing outer race
• ◆ Removing => Fig.1
• ◆ Pressing in => Fig.2
• Taper roller bearing inner race
• ◆ Pressing off => fig.3
• ◆ Pressing on => fig.4
• Input shaft
• ◆ Adjusting => Page 35-17

• 3rd gear
• ◆ Shoulder points to 4th gear
• ◆ Pressing off => Fig. 5
• ◆ Pressing on => Fig.7
• Circlip
• ◆ Always renew
• 4th gear
• ◆ Pressing off with taper roller bearing outer race and sleeve
  => Fig.5
• ◆ Pressing on => Fig.8
• ◆ Collar faces to 3rd gear
• Taper roller bearing inner race
• ◆ Pressing off with 4th gear wheel and sleeve => Fig.5
• ◆ Pressing on => Fig. 9
• Thrust washer
• Taper roller bearing outer race
• ◆ Pressing out => Fig.11
• ◆ Pressing in => Fig.12

• Shim
• ◆ Determining thickness => adjusting input shaft, Page 35-17
• Gearbox housing
• Sleeve
• ◆ For needle roller bearing
• ◆ Press off with 4th gear wheel and taper roller bearing inner race
  => Fig.5
• ◆ Pressing on => fig.10
• ◆ Place thrust washer on before installing (item 9)
• Needle roller bearing
• Selector gear for 5th gear
• ◆ Pull off together with 5th gear
  synchro-hub
  =>from Page 34-103

• 5th gear synchro-ring
• ◆ With cast locking pieces
  => Illustration N35-0018, Page 34-117
• ◆ Check for wear
  => Page 34-116
• Spring
• ◆ Installation position => Fig.14
• ◆ From gearbox build date 05 11 1 the spring has been modified
• Locking pieces (Qty. 3)
• ◆ Installation position => Fig.13
• ◆ From gearbox build date 05 03 1 locking pieces have been installed
• 5th gear synchro-hub
• ◆ Removing and installing
  => Page 34-103
• 5th gear locking collar
• ◆ Removing and installing
  

• Dished washer
• ◆ Installation position => Page 34-118
• Torx socket head bolt M 10,
  80 Nm
• ◆ Fitted piece on bolt head locates dished spring => Page 34-118

→ Fig.1     Pressing out taper roller bearing outer race

→ Fig.2     Pressing in taper roller bearing outer race

→ Fig.3     Pressing out taper roller bearing inner race

A - Separating device Kukko 17/1

→ Fig.4     Pressing on taper roller bearing inner race

→ Fig.5     Pressing off 4th gear wheel with taper roller bearing and sleeve

→ Fig.6     Pressing off 3rd gear wheel

→ Fig.7     Pressing on 3rd gear wheel

→ Fig.8     Pressing on 4th gear wheel

Shoulder points to 3rd gear.

→ Fig.9     Pressing on taper roller bearing inner race

→ Fig.10     Pressing on sleeve for needle roller bearing

→ Fig.11     Pressing out taper roller bearing outer race

→ Fig.12     Pressing in taper roller bearing outer race

• ‒ Install with shim after adjusting input shaft.

→ Fig.13     5th gear synchronizer

•      1 -     Springs for lock pieces
•      2 -     Locking collar
  With 3 recesses (arrows A) for the locking pieces (item 4)
•      3 -     Synchro-hub
•      4 -     Locking pieces
  Installation position: The thin extension (arrow B) faces the pointed teeth of the locking collar (item 2)

→ Fig.14     Assembling 5th gear locking collar/synchro-hub

• ‒ Push locking collar over synchro-hub.

Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. The recesses for the locking pieces in locking collar and synchro-hub must be aligned (Fig.13 ).

• ‒ Insert locking pieces (Installation position: Fig.13 ).
• ‒ Insert springs offset by 120° underneath lug -C-. The angled ends of the spring must be directly behind the locking pieces (arrows).
• ‒ Insert locking pieces (Installation position: Fig.13 ).