Volkswagen Workshop Service and Repair Manuals

Dismantling and assembling output shaft

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Press tool -VW 412-

t	Thrust pad -VW 512-

t	Puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t	Adapter -V.A.G 1582/5-

t	Pressure plate -VW 402-

t	Thrust piece -32 - 111-

t	Press tool -VW 408 A-

t	Press tool -VW 409-

t	Support rails -VW 457-

t	Tube -VW 519-

t	Drift sleeve -30 - 100-

t	Tube -VW 415 A-

t	Thrust pad -VW 447 H-

t	Thrust piece -VW 454-

t	Tube -2040-

t	Drift sleeve -41 - 501-

t  Internal puller -1-Kukko 21/6- t  Counter support -4-Kukko 22/2- t  Splitter -3-Kukko 17/2-

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

Pulling off small tapered roller bearing inner race A - Vice with protective jaws –  Fit adapter and tighten behind bearing rollers, then turn bearing and retighten gripping device.

Pressing on small tapered roller bearing inner race

Pressing off 3rd and 4th gear synchro-hub and locking collar, 2nd, 3rd and 4th gear synchromeshed gears with sleeve for gearbox housing needle bearing A -  Splitter, 22 … 115 mm, e.g. -Kukko 17/2- B -  Hexagon bolt M10 x 20, 17 mm AF   Note Support splitter so that the 1st and 2nd gear locking collar is not pulled off at the same time.

Pressing off locking collar with synchro-hub and bearing support –  First remove retaining ring -arrow-.

Pulling off large tapered roller bearing inner race A - Protective jaws –  Before fitting puller, insert a M10 x 20 hexagon bolt in the output shaft drilling.

Pressing on large tapered roller bearing inner race -A- Thrust washer –  Fit thrust washer before pressing on inner race. Shoulder faces inner race.

Installation position of outer ring, inner ring and synchro-ring for 1st gear –  Place inner ring -A- on synchromeshed gear for 1st gear. Angled lugs -arrow 1- face outer ring -B-. –  Fit outer ring -B-. Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed gear –  Fit synchro-ring -C-. Notches -arrow 4- engage in lugs -arrow 1- of inner ring -A-.   Note If components are not to be renewed, ensure that they are matched with their original gears.

Checking 1st and 2nd gear inner ring for wear –  Press inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation dimension	Wear limit
1st and 2nd gears	0.75 … 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchro-ring for wear –  Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap -a- using a feeler gauge.

Gap -a-	Installation dimension	Wear limit
1st and 2nd gears	1.2 … 1.8 mm	0.5 mm

Dismantling and assembling locking collar and synchro-hub for 1st and 2nd gears 1 -  Spring Allocate springs according to → Electronic parts catalogue „ETKA“. Installation with hollow locking pieces → Fig.. Installation with solid locking pieces → Fig.. 2 -  Locking collar 3 -  Synchro-hub 4 -  Locking piece Allocate locking pieces according to → Electronic parts catalogue „ETKA“. Collar is equally wide on both sides of synchro-hub. Collar has chamfer on one side -arrow B-. Chamfer on collar of synchro-hub and outer teeth of locking collar -arrow A- face in same direction after assembly. Notches -arrow C- in synchro-hub and sliding collar for locking pieces must align.

Assembly of 1st and 2nd gear locking collar and synchro-hub with hollow locking pieces l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Assembly of 1st and 2nd gear locking collar and synchro-hub with solid locking pieces l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces. -arrows-.

Installation position of locking collar with synchro-hub for 1st and 2nd gears Teeth of locking collar -arrow- face splines for 3rd and 4th gear synchro-hub -A-.

Pressing on locking collar and synchro-hub for 1st and 2nd gears Turn synchro-ring so that grooves align with locking pieces.

Installation position of 2nd gear outer ring Lugs -arrows- face 1st gear -A-.

Installation position of synchro-ring (2nd gear inner ring) -A- Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.

Installation position of synchromeshed gear for 2nd gear Higher shoulder -A- faces 1st gear -B-. Notches in shoulder -arrows- engage in lugs of outer ring → Fig..

Pressing on sleeve for 3rd gear needle bearing

Checking synchro-rings for 3rd and 4th gear for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap -a- using feeler gauge.

Gap -a-	Installation dimension	Wear limit
1st gear 3rd gear 4th gear	1.0 ... 1.7 mm 1.0 ... 1.7 mm 1.0 ... 1.7 mm	0.5 mm

Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub 1 -  Spring Allocate springs according to → Electronic parts catalogue „ETKA“. Installation with hollow locking pieces → Fig.. Installation with solid locking pieces → Fig.. 2 -  Locking piece Allocate locking pieces according to → Electronic parts catalogue „ETKA“. 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.

Assembly of 3rd and 4th gear locking collar and synchro-hub with hollow locking pieces Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Assembly of 3rd and 4th gear locking collar and synchro-hub with solid locking pieces l  Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Springs must seat with angled ends in front of locking pieces -arrows-.

Installation position of locking collar with synchro-hub for 3rd and 4th gears Chamfer -arrow- faces 4th gear.

Pressing on synchro-hub with locking collar for 3rd and 4th gears

Pressing on sleeve for 4th gear needle bearing

Pressing on sleeve for output shaft needle bearing