Volkswagen Workshop Service and Repair Manuals

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

• ◆ VW 407 Press tool
• ◆ VW 412 Press tool
• ◆ VW 512 Press disk
• ◆ V.A.G 1582 Puller
• ◆ V.A.G 1582/4 Grip piece
• ◆ V.A.G 1582/5 Grip piece

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

• ◆ VW 402 Thrust plate
• ◆ 32-111 Thrust piece
• ◆ VW 408 A Press tool
• ◆ VW 407 Press tool
• ◆ VW 457 Support rails
• ◆ VW 519 Tube

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

• ◆ VW 429 Thrust ring
• ◆ VW 415 A Tube
• ◆ VW 447 H Press plate
• ◆ VW 454 Press piece
• ◆ VW 455 Fitting sleeve
• ◆ 41-501 Drift sleeve

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

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

Notes:

• ◆ The output shaft is dismantled as follows:
  - Position separating device under 2nd gear wheel (item 19 ) and press off as described in fig. 5.
  - Remove circlip (item 15 ).
  - Pull off locking collar with 1st and 2nd gear synchro-hub as described in fig.6 .
• ◆ When installing new gears or a new output shaft consult technical data
  .
• ◆ Both taper roller bearings must be renewed together as a set.

• Hexagon nut, 25 Nm and then turn 90°further
• ◆ 4 nuts for bearing support
• Clutch housing
• Shim
• ◆ For output shaft
• ◆ Adjustment overview
  
• Small taper roller bearing outer race
• ◆ Removing => Fig.1
• ◆ Pressing in => Fig.2
• Small taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4

• Output shaft
• ◆ Is paired with final drive gear, always renew together as a set
• ◆ Adjusting => Page 35-56
• Large taper roller bearing inner race
• ◆ Pulling off => Fig. 7
• ◆ Pressing on => Fig.8
• Sealing ring
• ◆ Place sealing rings (Qty. 4) on the bearing support bolts
• Bearing support
• ◆ With large taper roller bearing outer race and bolts
• ◆ Only change outer race together with large taper roller bearing and bearing support

• Thrust washer
• ◆ Shoulder on thrust washer faces taper roller bearing
• 1st selector gear
• ◆ From gearbox build date 02 05 0 the synchronisation for the 1st gear has been modified
• Needle roller bearing
• ◆ For 1st gear
• 1st gear synchro-ring
• ◆ Checking for wear
  => Fig.9
• ◆ Identification => Fig.14
• ◆ From gearbox build date 02 05 0 the synchronisation for the 1st gear has been modified

• 1st and 2nd gear locking collar with synchro-hub
• ◆ Pull off with bearing support after removing the circlip (item 15 )
  => fig.6
• ◆ Dismantling => Fig.10
• ◆ Assembling locking collar/synchro hub => Fig.10 and Fig.11
• ◆ Installation position => Fig.12
• ◆ Pressing on => Fig.13
• ◆ From gearbox build date 02 05 0 the synchronisation for the 1st gear has been modified
• Securing clip
• 2nd gear synchro-ring
• ◆ Identification => Fig.14
• ◆ Checking for wear
  => Fig.16
• ◆ Assemble so that the recesses locate in the locking collar (item 14 ) locking pieces
• ◆ From gearbox build date 02 05 0 the synchronisation for the 1st gear has been modified

• Outer ring
• ◆ Insert in the synchro-ring (item 16 ). Installation position => Fig.17
• ◆ Renew if scored
• Synchro-ring
• ◆ (Inner ring)
• ◆ Checking for wear
  => Fig.18
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.19
• 2nd gear
• ◆ Installation position => Fig.20
• Needle roller bearing
• ◆ For 2nd gear
• Thrust washer

• Sleeve for 3rd gear needle roller bearing
• ◆ Pressing off with 2nd gear wheel
  => Fig.5
• ◆ Pressing on => Fig.21
• Needle roller bearing
• ◆ For 3rd gear
• Selector gear for 3rd gear
• 3rd gear synchro-ring
• ◆ Checking for wear
  => Fig.9
• Locking collar with 3rd and 4th gear synchro-hub
• ◆ Press off with 2nd (item 19) and 3rd gear selector gears (item 24) => fig.5
• ◆ Dismantling => Fig.22
• ◆ Installation position locking collar/synchro-hub => fig.24
• ◆ Assembling locking collar/synchro-hub => Fig.22 and Fig.23
• ◆ Pressing on => Fig.25

• Sleeve
• ◆ For needle roller bearing
• ◆ Press off with locking collar and 3rd and 4th gear synchro-hub (item 26)
  => Fig.5
• ◆ Pressing on => Fig.26
• Needle roller bearing
• ◆ For 4th gear
• 4th gear synchro-ring
• ◆ Checking for wear
  => Fig.9
• Selector gear for 4th gear
• Thrust washer
• Needle roller bearing
• ◆ For output shaft
• ◆ Removing and installing
  => Page 34-129
• Gearbox housing

• Sleeve
• ◆ For output shaft needle roller bearing
• ◆ Pressing off => Fig.5
• ◆ Pressing on => Fig.27
• 5th gear
• ◆ Removing and installing
  => Page 34-103
• Dished spring
• ◆ Installation position => Page 34-118
• Torx socket head bolt M10, 80 Nm
• ◆ Fitted portion on bolt head holds saucer spring washer in position

→ Fig.1     Pulling out small taper roller bearing outer race

A - Internal extractor 37 ... 46 mm, e.g. Kukko 21/6

B - Counter support, e.g. Kukko 22/2

→ Fig.2     Pressing in small taper roller bearing outer race

→ Fig.3     Pulling off small taper roller bearing inner race

A - Vice clamps/vice

• ‒ Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.

→ Fig.4     Pressing on small taper roller bearing inner race

→ Fig.5     Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with gearbox housing needle roller bearing sleeve

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

B - Hexagon bolt 17 mm AF - M10 x 20

Note:

Support separating appliance so that the 1st and 2nd gear locking collar is not pulled off at the same time.

→ Fig.6     Pulling off locking collar with synchro-hub and bearing support

• ‒ First remove circlip -arrow-.

→ Fig.7     Pulling off large taper roller bearing inner race

A - protective jaws

• ‒ Before fitting puller insert a M 10 x 20 hexagon bolt in the output shaft drilling.

→ Fig.8     Pressing on large taper roller bearing inner race

A - Thrust washer

• ‒ Fit thrust washer before pressing on the inner race. The shoulder faces the inner race.

→ Fig.9     Checking synchro-ring for wear

• ‒ Press synchro-ring onto the gear cone and measure gap "a" with feeler gauge.

→ Fig.10     Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub

•      1 -     Circlip
•      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.

→ Fig.11     Assembling 1st and 2nd gear locking collar/synchro-hub

• ● Locking collar is pushed over synchro-hub.

• ‒ Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow locking piece.

→ Fig.12     Installation position 1st and 2nd gear locking collar/synchro-hub

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-.

→ Fig.13     Pressing on 1st and 2nd gear locking collar/synchro-hub

Note:

Before pressing on, place 1st gear synchro-ring on 1st gear wheel.

→ Fig.14     Identifying 1st and 2nd gear synchro-rings

• ◆ 1st gear synchro-ring: 3 ground-down half teeth (arrow)
• ◆ 2nd gear synchro-ring: 3 ground down half teeth (arrow) or 2 ground-down half teeth

Only the version with 2 ground-down half teeth is available as a spare part for the 2nd gear synchro-ring.

→ Fig.15     Distinguishing 1st and 2nd gear synchro-rings

• ◆ 1st gear synchro-ring - no recesses
• ◆ 2nd gear synchro-ring - three recesses (arrows)

→ Fig.16     Checking 2nd gear synchro-ring for wear

• ‒ Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.

→ Fig.17     Installation position outer-ring

The lugs (arrows) face to 1st gear -A-

→ Fig.18     Checking inner ring for wear

• ‒ Press inner ring onto 2nd selector gear cone and measure gap "a" with a feeler gauge.

→ Fig.19     Installation position synchro-ring (inner-ring) -A-

The lugs (arrow 1) locate in the recesses (arrow 2) in the synchro-ring -B-.

→ Fig.20     Installation position 2nd gear wheel

The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate with the lugs of the outer-ring (arrow => Fig.17 )

→ Fig.21      Pressing on needle roller bearing sleeve for 3rd gear

→ Fig.22     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.

The recesses for locking pieces in synchro-hub and locking collar must align.

→ Fig.23     Assembling 3rd and 4th gear locking collar/synchro-hub

The locking collar has been pushed over the synchro-hub.

Locking pieces (hollowed)

• ‒ Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow locking piece.

Locking pieces (not hollowed)

• ‒ Insert locking pieces and install circlips 120° off-set. The angled end of the circlip must rest at front of the locking pieces.

→ Fig.24     Installation position 3rd and 4th gear locking collar/synchro-hub

Chamfer (arrow) faces to 4th gear.

→ Fig.25     Pressing on 3rd and 4th gear synchro-hub with locking collar

→ Fig.26     Pressing on sleeve for 4th gear needle roller bearing

→ Fig.27     Pressing on sleeve for output shaft needle roller bearing