Dismantling and assembling output shaft

Special tools and workshop equipment required

VW 407 Press tool

VW 408 A Press tool
VW 512 Thrust pad
V.A.G 1582 Puller
V.A.G 1582/5 Gripper
32-111 Pressing-on tool

VW 401 Pressure plate

VW 402 Pressure plate
VW 422 Tubular section
VW 447 H Thrust pad
30-100 Fitting sleeve
1 - Kukko 21/6 Internal puller
4 - Kukko 22/2 Support

Notes:

Heed technical data when installing new gear wheels or a new

output shaft
Output shaft has to be adjusted on replacing output shaft or
taper roller bearing
 1. Gearbox housing
2. Washer, Always 1 mm thick
3. Taper roller bearing outer race
4. Taper roller bearing inner race
5. Thrust washer
6. 1st speed sliding gear
7. Needle bearing For 1st gear
8. Synchro-ring (inner ring for 1st gear)
9. 1st gear outer ring
10. 1st gear synchro-ring
11. Circlip
12. Locking collar with synchro-hub
for 1st and 2nd gear
13. Spring
14. Locking collar
15. Synchro-hub
16. Locking piece (3x)
17. Spring
18. 2nd gear synchro-ring
19. 2nd gear outer ring
20. Synchro-ring (inner ring for 2nd gear)
21. 2nd speed sliding gear
22. Circlip
23. Needle bearing For 2nd gear
24. 3rd gear wheel
25. Circlip
27. 4th gear wheel
Identification groove faces final
drive toothing
28. Output shaft
Ensure correct ratio (number of
teeth)
29. Taper roller bearing inner race
30. Taper roller bearing outer race
31. Shim For output shaft
32. Clutch housing
33. Thrust washer. Shoulder of thrust washer faces taper roller bearing
34. Sleeve for needle bearing. Pressing off with 1st speed sliding gear
35. Needle bearing for 5th speed sliding gear
36. 5th speed sliding gear
37. 5th gear synchro-ring
38. Spring Position on 5th gear synchro-ring Replace if worn
39. 5th gear synchro-hub
40. 5th gear locking collar
41. Circlip
 → Fig.1 Pressing in taper roller
bearing outer race

→ Fig.2 Pressing off 1st speed sliding

gear with sleeve -1-, thrust washer -2-
and taper roller bearing inner/outer race
-3

→ Fig.3 Pressing circlip out of groove

A - Protective glove

Attention:
Make sure circlip does not spring off -
danger of accident.
→ Fig.4 Pressing off locking collar and
synchro-hub for 1st and 2nd gear

After removing circlip, jointly press off 2nd

speed sliding gear and locking
collar/synchro-hub.

→ Fig.5 Pulling off taper roller bearing

inner race

A - Soft jaws/vice

Fit gripper and tension firmly behind

rollers of bearing, then turn bearing
and re-tension gripper.

→ Fig.6 Pressing on taper roller

bearing inner race
→ Fig.7 Extracting taper roller bearing
outer race from clutch housing

A - Internal puller, e. g. Kukko 21/6, 37 ...

46 mm

B - Support, e.g. Kukko 22/2

→ Fig.8 Pressing in taper roller

bearing outer race

→ Fig.9 Inserting circlip

→ Fig.10 Checking 1st and 2nd gear
inner ring for wear

Press inner ring onto taper of 2nd

speed sliding gear and use feeler
gauge to measure gap "a".

→ Fig.11 Checking 1st and 2nd gear

synchro-ring for wear

Press synchro-ring, outer ring and

inner ring onto taper of sliding gear
and use feeler gauge to measure
gap "a".

→ Fig.12 Installation position of outer

ring, inner ring and synchro-ring for 2nd
gear

Position inner ring -A- on 2nd speed

sliding gear.

Angled webs (arrow 1) face outer ring -B-.

Fit outer ring -B-.

Webs (arrow 2) engage in sliding gear

recesses (arrow 3).

Fit synchro-ring -C-.

Recesses (arrow 4) engage in webs

(arrow 1) of inner ring -A-.
→ Fig.13 Dismantling and assembling
locking collar and synchro-hub for 1st
and 2nd gear

1- Spring
2- Locking collar
3- Synchro-hub
4- Locking piece

Slip locking collar over synchro-hub.

Smaller recesses for locking pieces in

synchro-hub and recesses in locking collar
must coincide.

→ Fig.14 Assembling locking

collar/synchro-hub for 1st and 2nd gear

Locking collar already slipped over

synchro-hub

Insert locking pieces in smaller

recesses and install springs with
120°offset. Angled end of spring
must engage in hollow locking piece.

→ Fig.15 Pressing on locking collar

with synchro-hub

Installation position:

Groove for selector fork in locking collar

facing 1st gear, toothing for reverse gear
facing 2nd gear

Turn synchro-ring such that grooves are

aligned with locking pieces.
→ Fig.16 Installation position of outer
ring for 1st gear

Lugs (arrows) face reverse gear toothing -

A-.

→ Fig.17 Installation position of

synchro-ring -A- (1st gear inner ring)

Lugs (arrow 1) engage in recesses (arrow

2) of synchro-ring -B-.

→ Fig.18 Installation position of 1st

speed sliding gear

Recesses in collar (arrows) engage in lugs

of outer ring
→ Fig.19 Pressing on taper roller
bearing inner race