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.