Operation CHARM: Car repair manuals for everyone.

Output Shaft, 5th, 6th and Reverse Gears






Output Shaft, 5th, 6th and Reverse Gears

Special tools, testers and auxiliary items required

Thrust Plate (VW 401)

Thrust Plate (VW 402)

Punch (VW 407)

Punch (VW 408A)

Thrust Disc (VW 412)

Tube 60 mm Dia. (VW 415A)

Holding Plate (VW 309)

Transmission Support (VW 353)

Thrust Pad Con. 8/65 (VW 433)

Thrust Tube (VW 454)

Support Channels (VW 457)

Holding Fixture (VW 801)

Thrust Pad 16.5/28 mm Dia. (VW 431)

Thrust Tube (VW 455)

Thrust Pad (VW 510)

Tube 42 mm Dia. (VW 516)

Sleeve (VW 519)

Thrust Pad (30-11)

Thrust Piece (40-105)

Sleeve (40-20)

Thrust Plate (2050)

Tube (3296)

Taper Roller Bearing Puller (V.A.G 1582)

Attachment to VAG 1582 (V.A.G 1582/4)

Grip (V.A.G 1582/7)

Kukko Extractor 46-58 mm (21/7)

Kukko Separating Tool (17/2)

Kukko Support (22/2)

Removing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing





- Before installing the puller, set the (30-11) onto the output shaft.

Installing the Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing





Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing





A Support, for example, (22/2)
B Internal puller 46 - 58 mm, for example, (21/7)

After pulling off, check the shim for damage and replace if necessary.

Pressing Outer Race/Tapered Roller Bearing into Clutch Housing





- Insert the shim under the outer race.

- Support the clutch housing directly beneath the bearing mount using the (40-20).

Remove the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing





Before installing the tapered roller bearing puller:

- Remove the inner race/tapered roller bearing locking ring on the side facing the transmission housing.

- Mount the (VW 431) and the (40-105) on the output shaft.

Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing





- Determine the circlip, refer to and install.

Determining the Circlip





- Determine thickest circlip which can still just be installed - and insert.

- Determine the circlip according to table. Part number, refer to the parts catalog.

Available Circlips





Pulling Outer Race/Tapered Roller Bearing out of Transmission Housing





A Support, for example, (22/2)
B Internal puller 46 - 58 mm, for example, (21/7)

Pressing Outer Race/Tapered Roller Bearing into Transmission Housing





- Support the transmission housing beneath the bearing mount using the (2050).

Output Shaft, Disassembly

Remove the inner race/tapered roller bearing on the side of the transmission housing, refer to.

Pressing off Synchronizer Hub/Locking Collar for 5th and 6th Gear with Selector Gear for 6th Gear





- Remove the circlip beforehand.

Pressing off Sleeve - A - over Reverse Gear Selector Gear





- Remove the circlip beforehand.

Pressing off Synchronizer Hub for Reverse Gear





- Remove the circlip beforehand.

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

Output Shaft, Assembly.

Installed Position of Synchronizer Hub for Reverse Gear





The stop - arrow A - for the reverse gear locking collar points toward the output shaft splines - arrow B -.

Pressing on Synchronizer Hub for Reverse Gear





- Install the circlip.

- Mount the reverse gear locking collar on the reverse gear synchronizer hub.

- Install the reverse gear wheel and the needle bearing.

Press on Sleeve - A -





Installed position: wide collar points toward the reverse gear selector gear.

- Install the circlip.

Checking Synchronizer Ring for 5th and 6th Gears for Wear





- Press the synchronizer ring onto the taper of the gear wheel and measure the gap dimension - a - using a feeler gauge.





Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears





1. Spring

2. Locking piece

3. Locking collar

4. Synchronizer hub

- Slide the locking collar over the synchronizer hub.

The recesses for the locking pieces in the synchronizer hub and locking collar must align.

Assembling Locking Collar/Synchronizer Hub for 5th and 6th Gears





The locking collar is pushed over the synchronizer hub.

- Insert the locking pieces and install the springs 120° offset. The spring must engage with the angled end into the hollow engaging piece.

- Install the 6th gear wheel with needle bearing.

- Install the 6th gear synchronizer ring.

Pressing on Locking Collar/Synchronizer Hub for 5th and 6th Gears





On some locking collars, there is a chamfer on the outer diameter.

Installed position: the chamfer on the outer diameter of the locking collar faces toward the 5th gear selector gear.

- Turn the synchronizer ring so that the grooves align with the locking pieces.

- Install the circlip.

- Install the 5th gear synchronizer ring.

- Install 5th gear selector gear with needle bearing.

Installing the inner race/tapered roller bearing on the side of the transmission housing, refer to.

Determining the locking ring for the inner race/tapered roller bearing, refer to.