Volkswagen Workshop Service and Repair Manuals

Repairing gearbox housing cover

Special tools and workshop equipment required t  Thrust plate -VW 401- t  Thrust plate -VW 402- t  Press tool -VW 407- t  Support bridge -2011- t  Internal puller -1 - Kukko 21/5- t  Counter support -4 - Kukko 22/1- t  In addition from gearbox date 21 08 6, assembly tool -3348/2-

1 -	Cylindrical roller bearing

q	For output shaft

q	Do not interchange with cylindrical roller bearing for input shaft

q	Pulling out → Fig.

q	Larger diameter from gearbox date 21 08 6 → Fig.

q	Pressing in through gearbox date 20 08 6: → Fig.

q	Pressing in from gearbox date 21 08 6: → Fig.

q	Locking → Fig.

2 -	Cylindrical roller bearing

q	For input shaft

q	Do not interchange with cylindrical roller bearing for output shaft

q	Pulling out → Fig.

q	Larger diameter from gearbox date 21 08 6 → Fig.

q	Pressing in through gearbox date 20 08 6: → Fig.

q	Pressing in from gearbox date 21 08 6: → Fig.

q	Locking → Fig.

3 -	Gearbox housing cover

q	Cylindrical roller bearings modified from gearbox date 21 08 6 → Fig.

Pulling cylindrical roller bearing out of gearbox housing cover A -  Internal puller, 30...37 mm, e.g. -Kukko 21/5- B -  Counter support, e.g. -Kukko 22/1-

Pulling cylindrical roller bearing out of gearbox housing cover A -  Internal puller, 30...37 mm, e.g. -Kukko 21/5- B -  Counter support, e.g. -Kukko 22/1-

Allocation of cylindrical roller bearings

Gearbox manufacture date	Dim. “a” mm	Dim. “b” mm
Through 20 08 6	43	43
From 21 08 6	47	47

Pressing cylindrical roller bearing into gearbox housing cover - through gearbox date 20 08 6 –  Heat gearbox housing cover with hot air blower -V.A.G 1416- in vicinity of bearing seat to about 100° C. –  Insert cylindrical roller bearing in heated housing and press in using workshop press until heat exchange has taken place.   Note Cylindrical roller bearings must be pressed into cover to stop.

Pressing cylindrical roller bearing into gearbox housing cover - from gearbox date 21 08 6 –  Heat gearbox housing cover with hot air blower -V.A.G 1416- in vicinity of bearing seat to about 100° C. –  Insert cylindrical roller bearing in heated housing and press in using workshop press until heat exchange has taken place.   Note Cylindrical roller bearings must be pressed into cover to stop.

Secure cylindrical roller bearing in gearbox housing cover by peening -arrows-