Output Shaft, 1ST-4TH Gear, Disassembling and Assembling
Output shaft, 1st-4th gear, disassembling and assembling
Special tools and equipment
^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Press tool
^ VW408 A Press tool
^ VW412 Press tool
^ VW415A Tube
Special tools and equipment
^ VW309 Holding plate
^ VW313 Support clamp
^ VW353 Transmission support
^ VW431 Press piece
^ VW433 Press piece
^ VW454 Press piece
Special tools and equipment
^ VW512 Press disk
^ VW516Tube
^ VW519 Tube
^ VW771 Multi-purpose tool
^ VW801 Holding plate
^ 40-105 Thrust plate
Special tools and equipment
^ 40-20 Press tool
^ 40-21 Press tool
^ 2050 Thrust piece
^ 3161 Extension
^ VAG1582 Tapered roller bearing puller
^ VAG1582/7 Grip
Special tools and equipment
^ 1 - Kukko 21/7 Internal puller
^ 1 - Internal puller Kukko 21/8
^ 2- Kukko18/2 Puller
^ 3- Kukko17/2 Separating device
^ 4- Kukko 22/2 Counter support
Note:
^ When installing new gears or a new output shaft consult technical data.
^ If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment.
1 - Clutch housing
2 - Oil deflector ring
3 - Dished washer
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
4 - Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 3
^ Pressing in, Refer to Fig. 4
5 - Tapered roller bearing inner race
^ Pressing off, Refer to Fig 8
^ Pressing on, Refer to Fig 9
6 - Output shaft
^ For 1st-4th gear
7 - Needle roller bearing
^ For 2nd gear
8 - 2nd gear
9 - Synchro-ring
^ (Inner ring for 2nd gear)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 12
10 - 2nd gear outer ring
^ Insert in the synchro-ring (item - 9 -)
^ Replace if scored
^ Installation position, Refer to Fig. 12
11 - 2nd gear synchro-ring
^ Checking for wear, Refer to Fig. 11
^ Installation position, Refer to Fig. 12
12 -1st and 2nd gear locking collar with synchro-hub
^ Pull off over bearing support after removing securing clip (item 13)
^ Disassembling, Refer to Fig. 13
^ Assembling locking collar/synchro hub Fig. 13 and, Refer to Fig. 14
^ Installation position, Refer to Fig. 15
^ Pressing on, Refer to Fig. 16
13 - Securing clip
14 -1st gear synchro-ring
^ Checking for Wear, Refer to Fig. 11
^ Assemble so that recesses locate in locking collar (item -12 -) locking pieces
15 - 1st gear outer ring
^ Insert in the synchro-ring (item -14 -), installation position , Refer to Fig. 17
^ Replace if scored
16 - Synchro-ring
^ (1st gear inner ring)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 18
17 - Needle roller bearing
^ For 1st gear
18 -1st selector gear
^ Installation position, Refer to Fig. 19
19 - Thrust washer
^ For 1stand 4th gear
^8GInsert lugs on thrust washer in holes on output shaft
20 - Shim
^ Holds thrust washer (-item 19 -) in position on output shaft
21 - Needle roller bearing
^ For 4th gear
22 - Selector gear for 4th gear
23 - 4th gear synchro-ring
^ Checking for wear, Refer to Fig. 22
24 - Locking collar with 3rd and 4th gear synchro-hub
^ Pull off by pulling off 4th gear wheel after removing the circlip (item - 25 -), Refer to Fig. 6
^ Disassembling, Refer to Fig. 13
^ Installation position locking collar/synchro-hub, Refer to Fig. 20
^ Assembling locking collar/synchro hub Fig. 13 and, Refer to Fig. 14
^ Pressing on, Refer to Fig. 21
25 - Securing clip
26 - 3rd gear synchro-ring
^ Checking for wear, Refer to Fig. 11
27 - Outer ring for 3rd gear
^ Insert in the synchro-ring (item - 26 -), installation position, Refer to Fig. 17
^ Replace if scored
28 - Synchro-ring
^ (3rd gear inner ring)
^ Checking for wear, Refer to Fig. 10
^ Check lugs for scoring
^ Installation position, Refer to Fig. 18
29 - Needle roller bearing
^ For 3rd gear
30 - Selector gear for 3rd gear
^ Installation position, Refer to Fig. 19
31 - Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 23
32 - Securing clip
^ Redetermine thickness if tapered roller bearing (-item 31 -) or output shaft (-item 6 -) are replaced, Refer to Fig. 24
33 - Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 25
^ Pressing in, Refer to Fig. 26
34 - Shim
35 - Transmission housing
Fig. 1 Pulling dished washer -A- out of output shaft
Fig. 2 Pressing dished washer -A- into output shaft onto stop
Fig. 3 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
A - Internal puller 56 to 70 mm, e.g. Kukko 21/8
Fig. 4 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press tool 40-20 directly below bearing mounting.
Fig. 5 Pulling off tapered roller bearing inner race
^ First remove securing clip.
^ Before mounting puller, position press piece VW 431 in output shaft and set thrust plate 40-105 on it.
Fig. 6 Pulling off 3rd and 4th gear synchro-hub/locking collar over 4th gear wheel
^ First remove securing clip.
A- Puller, e.g. Kukko 18/2
B - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 7 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. 8 Pulling off tapered roller bearing inner race
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 9 Pressing on tapered roller bearing inner race
Fig. 10 Checking inner ring for 1st, 2nd and 3rd gear for wear
^ Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.
Fig. 11 Checking 1st, 2nd and 3rd gear synchro-rings 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 gear wheel.
Angled lugs (arrow -1-) point toward outer ring -B-.
^ Install outer ring -B-.
Lugs (arrow -2-) engage in gear wheel recesses (arrow 3).
^ Install synchro-ring -C-.
The recesses (arrow -4-) engage in lugs (arrow -1-) of inner ring -A-.
Fig. 13 Disassembling and assembling 1st and 2nd as well as 3rd and 4th gear locking collar and synchro-hub
1 - Spring
2 - Locking piece
3- Locking collar
4 - Synchro-hub
^ Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.
Fig. 14 Assembling 1st and 2nd as well as 3rd and 4th gear locking collar/synchro-hub
The locking collar has been pushed over the synchro-hub.
^ Insert locking pieces and install springs 120° offset. Angled end of spring must locate in hollow locking piece.
Fig. 15 Installation position of 1st and 2nd gear locking collar/synchro-hub
Identification groove (arrow -1-) and narrow collar (arrow -2-) of synchro-hub point toward 1stgear.
Fig. 16 Pressing on 1st and 2nd gear locking collar/synchro-hub
^ Install securing clip.
Fig. 17 Installation position for 1st or 3rd gear outer ring
Lugs (arrows) face toward synchro-hub/locking collar -A-
Fig. 18 Installation position synchro-ring (inner ring for 1st or 3rd gear) -A-
The lugs (arrows -1-) engage in the recesses (arrow 2) in the synchro-ring -B-.
Fig. 19 Installation position 1st and 3rd gear wheel
The higher shoulder -A- faces toward 2nd or 4th gear -B-. The recesses in the shoulder (arrows) engage in the lugs of the outer ring (arrow 17)
Fig. 20 Installation position 3rd and 4th gear locking collar/synchro-hub
The wider shoulder of the synchro-hub (arrow) faces toward 3rd gear.
Fig. 21 Pressing on 3rd and 4th gear synchro-hub with locking collar
^ Install securing clip.
Fig. 22 Checking 4th gear synchro-ring for wear
^ Press synchro-ring onto gear cone and measure gap "a" with feeler gauge.
Fig. 23 Pressing on tapered roller bearing inner race
^ Determine securing clip, Refer to Fig. 24 and install it.
Fig. 24 Determining thickness of circlip
^ Determine thickest circlip which will still fit and install it.
The following securing clips are available:
Fig. 25 Pulling tapered roller bearing outer race out from transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Fig. 26 Pressing tapered roller bearing outer race into transmission housing
^ Install shim under outer race.
^ Support transmission housing with press piece 2050 directly below bearing support.