Output Shaft: Service and Repair

Disassembly/Assembly

Drive Pinion:

Legend 1:

Legend 2:

Legend 3:

NOTE:
- Items 1 through 18 are removed and installed without removing the drive pinion (refer to Legends 1 and 2).
- Different inner races (22) are used on the G50/50 turbo gearbox (refer to Legend 3).
- Refer to Legends for disassembly instructions, plus additional step below.

Disassembly





- Remove cylindrical roller bearing and four-point bearing with suitable separating tool (e.g. Kukko 15-17).

Assembly

NOTE: Assemble all drive-pinion components dry to prevent oil penetrating between the contact surfaces. Drive pinion and ring gear are marked with pairing numbers which must correspond when the components are assembled. Refer to Legends above for additional assembly instructions.





- Heat cylindrical roller bearing to approx. 12O°C and press on right way round.

NOTE: Install bearing with collar of roller cage facing gear set.





- Heat the inner race for the four-point bearing to approx. 120°C (250 °F) and press on using suitable pipe section (e.g. VW 519).





- Mount the driving dogs for the synchronization with the lug towards the gear shift sleeve, whereby the lug may point to either left or right.





- Check the synchronizer disks by pressing them on to the cones of the gear wheels and measuring distance 'A' with a feeler gauge.
A = Installation dimension:
(new) = min. 1.1 mm
Wear limit = 0.6-0.7 mm