Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ When installing new gears, consult technical data
  .
• ◆ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be re-adjusted. See adjustment overview

• Torx socket head bolt M 8,
  40 Nm
• ◆ Fitted piece on bolt head locates dished spring.
• Dished washer
• 5th gear
• ◆ Removing and installing
  => Page 34-73

• Taper roller bearing outer race
• ◆ Pressing out => Fig.1
• ◆ Pressing in => Fig.2
• Taper roller bearing inner race
• ◆ Pulling off => Fig.3
• ◆ Pressing on => Fig.4
• Gearbox housing
• Input shaft
• ◆ Adjusting => Page 35-13
• Needle roller bearing
• ◆ Lubricate before inserting
• Selector gear for 3rd gear
• ◆ Pressed off with locking collar/3rd and 4th gear synchro-hub => Fig.8 and pressed on => Fig.13

• 3rd gear synchro-ring
• ◆ Checking for wear
  => Fig.10
• Circlip
• ◆ Pressing out => Fig.7
• ◆ Inserting => Fig.9
• Locking collar with 3rd and 4th gear synchro-hub
• ◆ Parts are paired
• ◆ Pressing off => Fig.8
• ◆ Assembling => Fig.11 and Fig.12
• ◆ Pressing on => Fig.13
• Circlip
• ◆ Pressing out => Fig.7
• ◆ Inserting => Fig.9
• 4th gear synchro-ring
• ◆ Checking for wear
  => Fig.10

• Selector gear for 4th gear
• Needle roller bearing
• ◆ Lubricate before inserting
• Thrust washer
• Taper roller bearing inner race
• ◆ Can be removed without using tools
• Shim
• ◆ Determining thickness => Page 35-13
• Taper roller bearing outer race
• ◆ Pulling out => Fig.5
• ◆ Pressing in => Fig.6
• Clutch housing
• Spring
• ◆ Installation position => Fig.12

• Locking pieces (Qty. 3)
• Locking collar
• Synchro-hub
• Spring
• ◆ Installation position => Fig.12

→ Fig.1     Pressing out taper roller bearing outer race

→ Fig.2     Pressing in taper roller bearing outer race

→ Fig.3     Pulling off small taper roller bearing inner race

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

→ Fig.4     Pressing on small taper roller bearing inner race

→ Fig.5     Pulling out taper roller bearing outer race

A - Internal extractor 37 ... 46 mm, e.g. Kukko 21/6

B - Counter support, e.g. Kukko 22/2

→ Fig.6     Pressing in taper roller bearing outer race

→ Fig.7     Pressing circlip out of groove

→ Fig.8     Pressing off synchro-hub

• ‒ After removing securing ring press off synchro-hub and 3rd selector gear.

→ Fig.9     Inserting circlip

→ Fig.10     Checking synchro-ring for wear

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

→ Fig.11     Assembling locking collar and synchro-hub for 3rd and 4th gear

Installation position:

Short splines below circumferal groove (lower arrow) face 3rd gear.

Groove on end face (upper arrow) face 4th gear.

→ Fig.12     Locking collar/synchro-hub assembled

• ● Locking collar is pushed over synchro-hub.

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

→ Fig.13     Pressing on 3rd and 4th gear synchro-hub with locking collar