Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ When installing new gears or a new output shaft consult technical data
  .
• ◆ If the output shaft or taper roller bearings have been renewed then carry out output shaft adjustment .

• Gearbox housing
• ◆ Due to the new washer (item 2 ) the bearing seat for the taper roller bearing outer race has been made deeper by 1 mm from build date 08 07 7. This does not apply to gearbox "DQW"
• Washer
• ◆ Always 1 mm thick
• ◆ Installed from gearbox build date
  08 07 7, not applicable for gearbox "DQW"

• Outer race/taper roller bearing
• ◆ Pressing out of gearbox housing with output shaft => Page 34-88
• ◆ Pressing in => Fig.1
• Taper roller bearing inner race
• ◆ Pressing off with 1st selector gear
  => Fig.2
• ◆ Pressing on => Fig.19
• Thrust washer
• 1st selector gear
• ◆ Installation position => Fig.18
• Needle roller bearing
• ◆ For 1st gear
• Synchro-ring
• ◆ (1st gear inner ring)
• ◆ Checking for wear
  => Fig.10
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.17

• 1st gear outer ring
• ◆ Insert in the synchro-ring (item 10 ), installation position => Fig.16
• ◆ Renew if scored
• 1st gear synchro-ring
• ◆ Checking for wear
  => Fig.11
• ◆ Assemble so that the recesses locate in the locking collar (item 12 ) locking pieces
• Circlip
• ◆ Pressing out => Fig.3
• ◆ Inserting => Fig.9
• 1st and 2nd gear locking collar with synchro-hub
• ◆ Parts are paired
• ◆ Pressing off => Fig.4
• ◆ Assembling locking collar/synchro-hub => Fig.13 and Fig.14
• ◆ Pressing on => Fig.15

• Spring
• Locking collar
• Synchro-hub
• Locking pieces (Qty. 3)
• Spring
• 2nd gear synchro-ring
• ◆ Checking for wear
  => Fig.11
• ◆ Installation position => Fig.12
• 2nd gear outer ring
• ◆ Insert in the synchro-ring (item20 )
• ◆ Installation position => Fig.12
• ◆ Renew if scored

• Synchro-ring
• ◆ (2nd gear inner ring)
• ◆ Checking for wear
  => Fig.10
• ◆ Check lugs for scoring
• ◆ Installation position => Fig.12
• 2nd gear
• Circlip
• ◆ Pressing out => Fig.3
• ◆ Inserting => Fig.9
• Needle roller bearing
• ◆ For 2nd gear
• 3rd gear
• Circlip
• ◆ Pressing out => Fig.3
• ◆ Inserting => Fig.9
• Circlip
• ◆ Pressing out => Fig.3
• ◆ Inserting => Fig.9

• 4th gear
• ◆ Marked groove points towards final drive teeth
• Output shaft
• ◆ Ensure correct ratio (number of teeth) => Page 00-3 .
• ◆ Adjusting => Page 35-36
• Taper roller bearing inner race
• ◆ Pulling off => Fig.5
• ◆ Pressing on => Fig.6
• Outer race/taper roller bearing
• ◆ Removing => Fig.7
• ◆ Pressing in => Fig.8
• Shim
• ◆ For output shaft
• ◆ Determining thickness
  => Page 35-36
• Clutch housing

• Thrust washer
• ◆ Shoulder on thrust washer faces taper roller bearing
• Sleeve for needle roller bearing
• ◆ Pressing off with 1st selector gear
  => Fig.2
• ◆ Driving on => Page 34-96
• 5th selector gear needle roller bearing
• Selector gear for 5th gear
• 5th gear synchro-ring
• Spring
• ◆ Insert onto 5th gear synchro-ring
• ◆ Renew when worn
• 5th gear synchro-hub
• ◆ Removing => from Page 34-80

• 5th gear locking collar
• ◆ Removing => from Page 34-80
• Circlip
• ◆ Always renew
• ◆ Determining thickness => Page 34-98

→ Fig.1     Pressing in taper roller bearing outer race

→ Fig.2     Pressing off 1st gear sliding wheel with sleeve -1-, thrust washer -2-, taper roller inner/outer race -3-

→ Fig.3     Pressing circlip out of groove

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

After removing securing ring press 2nd selector gear and locking collar/synchro-hub off together.

→ Fig.5     Pulling off small taper roller bearing inner race

A - Vice clamps/vice

• ‒ Fit gripping device and tension behind bearing rollers, then turn bearing and retension gripping device.

→ Fig.6     Pressing on taper roller bearing inner race

→ Fig.7     Pulling taper roller bearing outer race out of clutch housing

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

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

→ Fig.8     Pressing in taper roller bearing outer race

→ Fig.9     Inserting circlip

→ Fig.10     Checking 1st and 2nd gear inner-ring for wear

• ‒ Press inner ring onto 2nd selector gear cone and measure gap "a" with a feeler gauge.

→ Fig.11     Checking 1st and 2nd gear synchro-ring for wear

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

→ Fig.12     Installation position of outer-ring, inner ring and 2nd gear synchro-ring

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

The angled lugs (arrow 1) point towards outer ring -B-.

• ‒ Fit outer ring -B-.

The lugs (arrow 2) engage in the selector gear recesses (arrow 3).

• ‒ Fit synchro-ring -C-.

The grooves (arrow 4) engage in the inner ring -A- lugs (arrow 1).

→ Fig.13     Dismantling and assembling 1st and 2nd gear synchro-hub and locking collar

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

• ‒ Slide locking collar over synchro-hub.

The small recesses for locking pieces in synchro-hub and locking collar must align with one another.

→ Fig.14     Assembling 1st and 2nd gear locking collar/synchro-hub

The locking collar has been pushed over the synchro-hub.

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

→ Fig.15     Pressing on locking collar/synchro-hub

Installation position:

Locking collar groove for selector fork towards 1st gear, the teeth for reverse gear towards 2nd gear.

Turn synchro ring so that the grooves align with the locking pieces.

→ Fig.16     Installation position for 1st gear outer-ring

The lugs (arrows) face towards reverse gear -A-.

→ Fig.17     Installation position synchro-ring -A- 1st gear (inner ring)

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

→ Fig.18     Installation position 1st selector gear

The recesses in the shoulder (arrows) locate in the lugs of the outer-ring (arrows => Fig.16 )

→ Fig.19     Pressing on taper roller bearing inner race