Volkswagen Workshop Service and Repair Manuals

Pinion shaft - disassemble and assemble

Special tools and workshop equipment required

t	Plate -VW 402-

t	Pressure pin -VW 407-

t	Pressure disc -VW 412-

t	Pressure tube -VW 415A-

t	Pressure base -VW 432-

t	Supporting tube -40-21-

t  -1-Puller 30 - 37mm or VW 020P - Kukko 21/5-

t  -4-Auxiliary support -KUKKO 22/1 -   Note t  When installing new gears or a new pinion shaft, refer to technical data → Chapter. t  Install all the bearings, gears and synchroniser rings on the primary shaft, lubricated with gear oil. t  Do not invert the synchroniser rings. When reusing synchronizer rings, always install them on the same gear pair.

1 -	Clutch case

2 -	Tapered roller bearing

q	With circlip

q	Removal → Fig.

q	Installation → Fig.

q	Installation position: the circlip shall face the pinion shaft

3 -	Pinion shaft

q	If replacement is required, the differential master gear must also be replaced → Item.

q	If there is an inside ring as tapered roller bearing housing, this should not be removed from the pinion shaft.

q	If scratches or damages are detected on the bearing housing or inside ring, replace the pinion shaft and the tapered roller bearing as a set.

4 -	4th gear wheel

q	Installation position: the hub shall face the 3rd gear → Fig.

5 -

Circlip

6 -

Circlip

7 -	3rd gear wheel

q	Installation position: the hub shall face the 3rd gear → Fig.

8 -

Circlip

9 -	2nd gear wheel

10 -	Needle bearing

q	For 2nd gear

11 -	Inside ring for 3rd gear

q	Wear check → Fig.

q	Installation position → Fig.

12 -	Outside ring for 2nd gear

q	Install on inside ring → Item

q	Change in case of scratches or wear signs

q	Installation position → Fig.

13 -	Synchroniser ring for 2nd gear

q	Wear check → Fig.

q	Installation position → Fig.

14 -	Engaging sleeve with 1st and 2nd gear synchroniser

q	Remove with 2nd gear wheel after removing the circlip → Fig.

q	Disassemble and assemble the engaging sleeve/synchroniser ring → Fig.

q	Installation → Fig.

15 -

Circlip

q	Removal → Fig..

q	Installation → Fig.

16 -	Synchroniser ring for 1st gear

q	Wear check → Fig.

q	Install in order that the notches fit in the engaging sleeve limiters → Item

17 -	Outside ring for 1st gear

q	Install on synchroniser ring → Item

q	Installation position → Fig.

q	Change in case of scratches or wear signs

18 -	Inside ring for 1st gear

q	Wear check → Fig.

q	Check the flanges for wear signs

q	Installation position → Fig.

19 -	Needle bearing

q	For 1st gear

20 -	1st gear wheel

q	Installation position → Fig.

21 -	Bearing support with ball bearing

q	Change bearing support with ball bearing

q	Clean the threaded holes of the bearing support (e.g. Tap M6)

q	Removal → Fig..

q	Installation → Fig.

22 -	Transmission case

23 -	5th gear wheel

q	Installation position: the hub shall face the transmission case side → Fig.

24 -

Circlip

q	Always replace

q	Determine thickness → Anchor

25 -

Spring

q	Installation position → Fig.

26 -	Engaging sleeve

27 -	Synchroniser

28 -

Retainers

q

3 units

Removing tapered roller bearing on clutch case A -  Auxiliary support -KUKKO 22/1- B -  Puller 30 - 37mm or VW 020P -Kukko 21/5- –  When removing it, compress the bearing circlip -arrow- with pliers -C-.

Installing the tapered roller bearing on clutch case –  Support the clutch case by placing the Pressure tube -VW 415A- (not shown in fig.) directly under the bearing support. –  When installing, compress the bearing circlip -arrow- with pliers -A-. –  Remove the pliers just before the bearing is in the correct installation position. The circlip shall be locked in the clutch case hole.

Removing circlip -1- from notch A -  Safety sleeve B -  Multi-purpose pliers   WARNING Avoid uncontrolled motions of circlip.

Removing 1st and 2nd engaging sleeve/synchroniser –  After removing the circlip, disengage with the moving wheel of the 2nd gear and the engaging sleeve with synchroniser.

Installation position of 3rd and 4th gear wheels –  Install 4th gear wheel -A- on pinion shaft. The collar -arrow 1- shall face the 3rd gear wheel -B-. –  Install circlips -2- and -3-. –  Install 3rd gear wheel -B- on pinion shaft. The hub -arrow 2- shall face the 4th gear wheel -A-. –  Install circlip -1-.

Checking 1st and 2nd gear inside ring wear –  Press the inside ring against the gear cone and measure the distance -a- with a feeler gauge.

Distance -a-	New part	Wear limit
1st and 2nd gears	0,75 ... 1.25 mm	0.3 mm

Checking 1st and 2nd gear synchroniser ring wear –  Press the synchroniser ring, internal and external tracks against the gear cone and measure the distance -a- with a feeler gauge.

Distance -a-	New part	Wear limit
1st and 2nd gear	1,2 ... 1.8 mm	0.5 mm

Installation position of the outside and inside rings of the 2nd gear synchroniser ring –  Install inside ring -A- on the 2nd gear wheel. The curve shoulders -arrow 1- shall face the outside ring -B-. –  Install the outside ring -B- over. The flanges -arrow 2- shall fit in the grooves -arrow 3- of the gear. –  Install the synchroniser ring -C- over. The grooves -arrow 4- shall fit in the relieves -arrow 1- on inside ring -A-.

Disassembling and assembling the 1st and 2nd gear engaging sleeve and synchroniser 1 -  Spring 2 -  Engaging sleeve 3 -  Synchroniser 4 -  Limiter –  Press the engaging sleeve on the synchroniser. The notch on front face -arrow A- and the wide collar -arrow B- shall face the external teeth on the engaging sleeve -arrow C- after installing. The deeper grooves -arrow D- for the limiters located on the synchroniser shall match the grooves -arrow E- on the engaging sleeve. –  Install the limiters in the deeper grooves -arrows-.

Mounting 1st and 2nd engaging sleeve/synchroniser l  Press the engaging sleeve on the synchroniser –  Install the limiters in the deeper grooves -arrows-. –  Install springs -B- and -C- displaced by -a-   Note -a- = 120° –  The folded end of the spring shall fit into the limiter's hole.

Installing 1st and 2nd engaging sleeve/synchroniser Installation position: The notch for the selection fork located on the engaging sleeve shall face the 1st gear and the teeth for reverse gear towards 2nd gear. –  Turn the synchroniser ring in order to match flanges and limiters.

Installing circlip –  Install the 1st gear circlip on the engaging sleeve/synchroniser.

Installation position of the 1st gear outside ring The flanges -arrows- shall face the teeth for reverse gear.

Installation position of the 1st gear inside ring -A- The flanges -arrow 1- fit in the notches -arrow 2- on synchroniser ring -B-.

Installation position for 1st gear moving wheel The tall collar -A- shall face the 2nd gear -B-. The collar notches -arrows- fit on the outside ring flanges -arrow-.