Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Drift -VW 295-

t	Thrust pad -VW 512-

t	Press tool -VW 408 A-

t	Press tool -VW 411-

t	Press tool -VW 407-

t	Drift sleeve -41 - 501-

t  Thrust plate -VW 402-

t  Tube -VW 516-

t	When installing new gear wheels or a new output shaft, consult technical data → Chapter.

t	If output shaft or tapered roller bearings have been renewed, adjust output shaft → Chapter.

1 -	Gearbox housing cover

2 -	Retaining ring for gear wheel for 5th gear

q

Renew.

3 -	Thrust washer

4 -	Gear wheel for 5th gear

q	Installing → Chapter

5 -	Gearbox housing

6 -	Needle bearing

q	Removing and installing → Fig.

7 -	Retaining ring for gear wheel for 4th gear

q

Renew.

8 -	Gear wheel for 4th gear

9 -	Retaining ring for gear wheel for 3rd gear

q

Renew.

q	Redetermining thickness → Chapter

10 -	Gear wheel for 3rd gear

q	Installation position → Chapter

q	Adjusting axial play → Chapter.

11 -	2nd gear synchromeshed gear

12 -	Needle bearing for 2nd gear synchromeshed gear

q	Pulling off inner race → Chapter.

q	Pressing on inner race → Chapter.

13 -	Synchro-ring for 2nd gear

q	Check for wear → Fig.

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

q	Assembling locking collar and synchro-hub → Fig. and → Fig.

q	Removing and installing → Chapter

15 -	Synchro-ring for 1st gear

q	Check for wear → Fig.

q	Identification → Fig.

16 -	Synchromeshed gear for 1st gear

17 -

Spring

18 -	Locking collar

19 -	Synchro-hub

20 -	Locking pieces (Qty. 3)

21 -	Needle bearing

q	For 1st gear

22 -	Thrust washer

q	Installation position → Chapter

23 -	Clutch housing

24 -

Shim

q	For output shaft

q	Adjustment overview → Chapter

25 -	Small tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig..

26 -	Small tapered roller bearing inner race

q	Pressing off → Fig..

q	Pressing on → Fig.

27 -	Output shaft

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

q	Adjusting → Chapter

28 -	Large tapered roller bearing inner race

q	Pressing off → Fig..

q	Pressing on → Fig.

29 -	Bearing support

q	With large tapered roller bearing outer race and stop for reverse gear wheel.

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

30 -	Hexagon bolt, 25 Nm and turn 90° further

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 and 2nd gears	1.1…1.7 mm	0.5 mm

Identifying 1st gear synchro-ring Identification: 1 tooth -arrow- each missing in three places. This synchro-ring must be fitted only to 1st gear.

Assembling 1st and 2nd gear locking collar and synchro-hub Installation position of synchro-hub: Identification groove on face side -arrow- faces outer splines of locking collar. –  Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.

Assembling locking collar with synchro-hub for 1st and 2nd gears –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

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

Pressing in small tapered roller bearing outer race

Pressing off small tapered roller bearing inner race A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-

Pressing off large tapered roller bearing inner race A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2-   Note Inner race can also be pulled off using tapered roller bearing puller -V.A.G 1582- and adapter -V.A.G 1582/7-.

Heating small and large taper roller bearing inner races to about 100° C, fitting and pressing home