Volkswagen Workshop Service and Repair Manuals

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

• ◆ VW 401 Thrust plate
• ◆ VW 402 Thrust plate
• ◆ VW 407 Press tool
• ◆ VW 412 Press tool
• ◆ VW 415 A Tube
• ◆ VW 422 Tube

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

• ◆ VW 472/2 Spacer sleeve
• ◆ VW 516 Tube
• ◆ 30-23 Extension
• ◆ 30-100 Drift sleeve
• ◆ T10080 Press tool
• ◆ T10081 Press tool

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

• ◆ 2010 Tube
• ◆ T10083 Press support
• ◆ T10084A Thrust plate
• ◆ 1 - Kukko 21/5 Internal puller
• ◆ 4 - Kukko 22/1 Counter-support

Notes:

• ◆ When installing new gears, consult technical data
  .
• ◆ Fit all bearings, selector gears and synchro-rings on the input shaft with gearbox oil.
• ◆ Do not fit synchro-rings in wrong order. If rings do not require renewal, always allocate them to the original selector gear.

• Circlip
• ◆ Always renew
• ◆ Determining thickness
• 5th gear locking collar/synchro-hub
• ◆ Removing and installing
  => from page 34-59
• ◆ Dismantling => fig.16
• ◆ Joint installation of 5th gear locking collar/synchro-hub => Fig.16 and => Fig.17
• ◆ Installation position => fig.16

• 5th gear synchro-ring
• ◆ Checking for wear => fig.8
• Selector gear for 5th gear
• Needle roller bearing
• ◆ For 5th gear
• ◆ Renew together with item 6
• Sleeve
• ◆ For 5th gear needle roller bearing
• ◆ Renew together with item 5
• ◆ Press off with bearing mounting/grooved ball bearings => fig.3
• ◆ Pressing on => fig.14
• Gearbox housing

• Bearing support with grooved ball bearings
• ◆ Only renew grooved ball bearings together with bearing mounting
• ◆ If bearing mounting is separated from gearbox housing, it must always be renewed
• ◆ Pressing off => fig.3
• ◆ Pressing on => fig.13
• Input shaft
• Needle roller bearing
• ◆ For 3rd gear
• Selector gear for 3rd gear
• 3rd gear synchro-ring
• ◆ Checking for wear => fig.8

• 3rd and 4th gear locking collar and synchro-hub
• ◆ Press off with selector gear for 3rd gear=> fig.4
• ◆ Dismantling => fig.5
• ◆ Installation position locking collar/synchro-hub => fig.7
• ◆ Assembling => fig.6
• ◆ Pressing on => fig.9
• 4th gear synchro-ring
• ◆ Checking for wear => fig.8
• Selector gear for 4th gear
• Sleeve
• ◆ For 4th gear needle roller bearing
• ◆ Renew together with item 17
• ◆ Press off with selector gear for 3rd gear=> fig.4
• ◆ Pressing on => fig.10

• Needle roller bearing
• ◆ For 4th gear
• ◆ Renew together with item 16
• Thrust washer
• Inner racer of roller bearing
• ◆ Pressing off => fig.4
• ◆ Pressing on => fig.11
• Circlip
• ◆ Renew
• ◆ Determining thickness => page12
• Roller bearing
• ◆ With circlip
• ◆ Pulling out => fig.1
• ◆ Pressing in => fig.2
• ◆ Fitting location: The circlip in the bearing faces the input shaft

• Clutch housing
• Spring
• ◆ Installation position => fig.6
• 3rd and 4th gear locking collar
• 3rd and 4th gear synchro-hub
• Locking pieces (Qty. 3)
• Spring
• ◆ Installation position => fig.17
• Locking pieces (Qty. 3)
• 5th gear synchro-hub
• 5th gear locking collar
• Check ring
• ◆ Prevents the locking pieces drifting out
• ◆ Removing =>Fig.15
• ◆ Installing => Fig.18

→ Fig.1     Pulling roller bearing out from clutch housing

• ‒ When removing, press circlip -arrow- of roller bearing together using pliers -C-.

A - Counter support, e.g. Kukko 22/1

B - Internal puller 30...37 mm, e.g. Kukko 21/5

→ Fig.2     Pressing roller bearing into clutch housing

• ‒ Support clutch housing using tube VW 415 A (not visible in diagram) directly under the bearing mounting.
• ‒ When pressing in, press circlip -arrow- of roller bearing together using pliers.
• ‒ Remove pliers just before roller bearing is in position. The circlip must locate in the groove of the clutch housing.

→ Fig.3     Pressing off bearing mounting and grooved ball bearings

• ‒ Slide locking collar for 1st and 2nd gear to 2nd gear.
• ‒ Slide thrust plate T10084A sideways onto stop on input shaft.
• ‒ Insert centring pin in thrust piece T10081 in holes of input and output shaft.

→ Fig.4     Pressing off roller bearing inner race

• ‒ Remove circlip.
• ‒ Press off roller bearing inner race together with
       - thrust washer
       - selector gear for 4th gear with needle roller bearing
       - locking collar and synchro-hub for 3rd and 4th gear
       - and selector gear for 3rd gear.

→ Fig.5     Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub

•      1 -     Circlip
•      2 -     Locking collar
•      3 -     Synchro-hub
•      4 -     Locking piece

• ‒ Slide locking collar over synchro-hub.

The deeper recesses -arrow A- for the locking pieces in the synchro-hub must align with the recesses -arrow B- in the locking collar.

→ Fig.6     Assembling 3rd and 4th gear locking collar/synchro-hub

• ● Locking collar is pushed over synchro-hub.

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

→ Fig.7     Installation position 3rd and 4th gear locking collar/synchro-hub

The groove on the top (arrow B) points towards 4th gear.

→ Fig.8     Checking synchro-ring for wear

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

→ Fig.9     Pressing on 3rd and 4th gear synchro-hub and locking collar

→ Fig.10     Pressing on sleeve -A- for 4th gear needle roller bearing

• ‒ After pressing on sleeve -A-, install 4th gear needle roller bearing with selector gear for 4th gear and thrust washer.

→ Fig.11     Pressing on roller bearing inner race -A-

→ Fig.12     Determining thickness of circlip

• ‒ Insert a 2.0 mm thick circlip -A- in groove of input shaft and press upwards -arrow-.
• ‒ Determine distance between inner ring -B- and fitted circlip -A- using feeler gauge -C-.
• ‒ Remove circlip used for measurement.
• ‒ Use table to determine circlip.

Note:

Allocate circlips according to parts catalogue.

Available circlips

→ Fig.13     Pressing on bearing mounting with grooved ball bearings

• ‒ Before pressing on, heat bearing mounting to approx. 100° C.

→ Fig.14     Pressing on sleeve -A- for 5th gear needle roller bearing

→ Fig.15     Removing thrust ring

• ‒ Unclip hooks -A- of check ring from synchro-hub using a screwdriver.

→ Fig.16     Dismantling and assembling 5th gear locking collar and synchro-hub

•      1 -     Circlip
•      2 -     Locking piece
•      3 -     Synchro-hub
• Installation location: The groove on the top -arrow A- and the wide collar -arrow B- face the 5th gear
•      4 -     Locking collar
•      5 -     Check ring

• ‒ Slide locking collar over synchro-hub.

The deeper recesses -arrow C- for the locking pieces in the synchro-hub must align with the recesses -arrow D- in the locking collar.

→ Fig.17     Assembling 5th gear locking collar/synchro-hub

• ● Locking collar is pushed over synchro-hub.

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

→ Fig.18     Installing check ring

• ‒ Press check ring onto tube 2010.
• ‒ Insert check ring together with tube 2010 into 5th gear synchro-hub/locking collar (observe installation location => Fig.16 ).

• The hooks -arrow 1- locate in recesses -arrow 2- of synchro-hub locking pieces.

• ‒ Press down check ring until the hooks lock into place.