Volkswagen Workshop Service and Repair Manuals

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

• ◆ VW 402 Thrust plate
• ◆ VW 407 Press tool
• ◆ VW 412 Press tool
• ◆ VW 415 A Tube
• ◆ VW 432 Press piece
• ◆ 40-21 Press tool

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

• ◆ 1 - Kukko 21/5 internal puller
• ◆ 4 - Kukko 22/1 counter-support

Notes:

• ◆ When installing new gears or a new output shaft consult technical data
  .
• ◆ Fit all bearings, selector gears and synchro-rings to output shaft with gearbox oil.
• ◆ Do not interchange synchro-rings. If rings do not need renewing, fit to original selector gear.

• Clutch housing
• Roller bearing
• ◆ With circlip
• ◆ Pulling out => Fig.1
• ◆ Pressing in => Fig.2
• ◆ Fitting location: The circlip in the bearing faces the output shaft

• Output shaft
• ◆ When an inner race, which is used as a bearing seat for the cylinder roller bearing (item 2 ), then it cannot be removed from output shaft
• ◆ Check bearing seat or inner race as applicable for scoring and damage
• ◆ If bearing seat/inner race scored or damaged replace output shaft and cylinder roller bearing together
• 4th gear
• ◆ Fitting location: Collar faces 3rd gear => Fig.5
• Circlip
• Circlip

• 3rd gear
• ◆ Fitting location: Collar faces 4th gear => Fig.5
• Circlip
• Selector gear for 2nd gear
• Needle roller bearing
• ◆ For 2nd gear
• 2nd gear inner ring
• ◆ Checking for wear
  => Fig.6
• ◆ Installation position => Fig.8
• 2nd gear outer ring
• ◆ Place on inner ring -item 11 -
• ◆ Renew if scored
• ◆ Installation position => Fig.8
• 2nd gear synchro-ring
• ◆ Checking for wear
  => Fig.7
• ◆ Installation position => Fig.8

• 1st and 2nd gear locking collar with synchro-hub
• ◆ Press off together with selector gear for 2nd gear after removing the circlip (item15 )
  => Fig.4
• ◆ Dismantling => Fig.9
• ◆ Assembling locking collar/synchro hub => Fig.9 and Fig.10
• ◆ Installation position => Fig.9
• ◆ Pressing on => Fig.11
• Securing clip
• ◆ Removing => Fig.3
• ◆ Inserting => Fig.12
• 1st gear synchro-ring
• ◆ Checking for wear
  => Fig.7
• ◆ Insert so that the locking pieces of the locking collar locate in the inserts -item 14 -

• 1st gear outer ring
• ◆ Insert in synchro-ring (item 16 ). Installation position => Fig.13
• ◆ Renew if scored
• 1st gear inner ring
• ◆ Checking for wear
  => Fig.6
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.14
• Needle roller bearing
• ◆ For 1st gear
• 1st selector gear
• ◆ Installation position => Fig.15

• Bearing mounting 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 => Page 35-16 , Fig.13
• Gearbox housing
• 5th gear wheel
• ◆ Installation position: Collar faces gearbox casing cover => Page 34-71
• Circlip
• ◆ Always renew
• ◆ Determining thickness => Page 34-71

• Spring
• ◆ Installation position => Fig.10
• Locking collar
• Synchro-hub
• Locking pieces (Qty. 3)

→ Fig.1     Pulling roller bearing out of clutch housing

• ‒ When pulling out, press roller bearing circlip -arrow- 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 in clutch housing

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

→ Fig.3     Removing circlip -1- from groove

•      A -     Protective glove

→ Fig.4     Pressing off 1st and 2nd gear locking collar/synchro-hub

• ‒ When circlip has been removed, press off selector gear for 2nd gear together with locking collar/synchro-hub.

→ Fig.5     Installation position of 3rd and 4th gear wheel

• ‒ Fit 4th gear wheel -A- onto output shaft.

Installation position:

Collar -arrow 1- faces 3rd gear wheel -B-.

• ‒ Fit circlips -2- and -3-.
• ‒ Fit 3rd gear wheel -B- onto output shaft.

Installation position:

Collar -arrow 2- faces 4th gear wheel -A-.

• ‒ Fit circlip -1-.

→ Fig.6     Checking 1st and 2nd gear inner ring for wear

• ‒ Press inner ring onto cone of selector gear and measure gap "a" using a feeler gauge.

→ Fig.7     Checking 1st and 2nd gear synchro-ring for wear

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

→ Fig.8     Installation position of outer ring, inner ring and synchro-ring of 2nd gear

• ‒ Place inner ring -A- on selector gear of 2nd gear.

• The angled tabs -arrow 1- point towards the outer ring -B-.

• ‒ Fit outer ring -B-.

• The tabs -arrow 2- lock in the recesses -arrow 3- of the selector gear.

• ‒ Fit synchro-ring -C-.

• The recesses -arrow 4- locate on the tabs -1- of the inner ring -A-.

→ Fig.9     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.

Installation position:

The groove on the top -arrow A- and the higher collar -arrow B- of the synchro-hub face the gear teeth of the locking collar when fitted together -arrow C-.

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

→ Fig.10     Assembling 1st and 2nd gear locking collar/synchro-hub

• ● Locking collar is pushed over synchro-hub.

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

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

Installation position:

The groove in the locking collar for the selector fork faces the 1st gear and the reverse gear teeth face the 2nd gear.

• ‒ Turn synchro-ring so that the grooves are flush with the locking pieces.

→ Fig.12     Inserting circlip

• ‒ Fit 1st gear synchro-ring in locking collar/synchro-hub.

→ Fig.13     Installation position for 1st gear outer ring

The lugs (arrows) face the gear teeth of the reverse gear

→ Fig.14     Installation position of 1st gear inner ring -A-

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

→ Fig.15     Installation position of selector gear for 1st gear

The higher collar -A- faces the 2nd gear -B-. The recesses in the collar (arrows) locate with the tabs of the outer ring (arrow => Fig.13 )