Output Shaft

Output Shaft

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Thrust Disc (VW 412)

• Tube 60 mm Dia. (VW 415 A)

• Sleeve (VW 519)

• Slide Hammer-Complete Set (VW 771)

• Driving Sleeve (32 - 109)

• Sleeve (40 - 21)

• Seal Driver (3013)

• Tube (3296)

• - 1 - Internal Puller (Kukko 21/1)

• - 3 - Separating Tool (Kukko 17/2)

• Inductive Heater (VAS 6414)

• Removing and installing 1st, 2nd and reverse gears. Refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts.

Remove the 3rd and 4th gear wheels and the roller bearings from the output shaft.

- Remove the 4th gear wheel locking ring.

Removing the 4th Gear Wheel





- Remove the spacer sleeve - 33 - => [ Spacer Sleeve ] Output Shaft Assembly Overview from the output shaft by hand.

Removing the 3rd Gear Wheel





A Separating device 22 to 115 mm, for example (Kukko 17/2)

Removing the Roller Bearing from the Output Shaft





A Separating device 22 to 115 mm, for example (Kukko 17/2)

• The roller bearing will get damaged when it is being removed, therefore always replace it.

• The roller bearing cage can also get damaged when removing using a screwdriver. Then mount the separating tool on the inner race.

Install the 3rd and 4th gear wheels and the roller bearings on the output shaft.

Installing the Roller Bearing on the Output Shaft





Pressing on Gear-Wheel for 3rd Gear





• Installation position:

High inner collar faces 4th gear.

- Install the spacer sleeve - 33 - => [ Spacer Sleeve ] Output Shaft Assembly Overview on the output shaft by hand.

Pressing on Gear-Wheel for 4th Gear





• Installation position:

The high inside collar faces upward, to the groove for the locking ring

- Install the 4th gear wheel locking ring.

• When replacing the output shaft, the spacer sleeve or the 3rd or 4th gear wheels:

Determine the 4th Gear Wheel Locking Ring.





• The gear wheel is installed all the way.

• The 4th gear wheel locking ring is determined the same as with the synchronizer hub.

- Determine thickest circlip which can still just be installed and insert it. For the part number, refer to the electronic parts catalog ETKA

The following locking rings are available:






Flange Shaft Mounting Needle Bearing, Removing from Output Shaft





A Internal puller 12 to 14.5 mm, for example (Kukko 21/1)

Flange Shaft Mounting Needle Bearing, Driving in Flush in the Output Shaft





Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards (3013).