Disassembly and Assembly

Output Shaft

Special tools, testers and auxiliary items required

• Pressure plate (VW 401)

• Pressure plate (VW 402)

• Punch (VW 412)

• Sleeve (VW 415 A)

• Alignment fixture (3292/4)

• Assembly sleeve (T10290)

• Alignment fixture (T40088/2)

• Alignment fixture (T40211)

• Puller (Kukko 20-10)

• 200 mm hook (Kukko)

• Inductive heater (VAS 6414)

• Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.

• Before installing the roller bearing inner races, warm to a maximum of 100 °C while wearing protective gloves.

• Warm synchronizer ring before pressing off to a maximum of 100 °C while wearing protective gloves.

• Always press the roller bearing inner race and synchronizer hub all the way on so that the gear wheels have the specified axial play.

Removing the 1st Gear Wheel

1 Reverse gear nut
2 Washer
A Two-Arm Puller (Kukko 20-10)

- Secure the output shaft - 3 -, the washer - 2 - and the nut - 1 - to the fitting appliance.

- Remove the roller bearing inner race together with the 1st gear wheel.

Removing the Synchronizer Hub and 1st and 2nd Gear Locking Collar

1 Two-Arm Puller (Kukko 20-10)
2 200 mm hook

• Mark the installation position.

- Remove the needle bearing and 1st gear synchronizer rings

- Remove circlip.

- Remove the synchronizer hub and locking collar with the 2nd gear wheel.

Removing the 3rd and 4th Gear Wheel

Installing the 3rd and 4th Gear Wheel

- Warm the 3rd and 4th gear wheel to approximately 130 °C. Wear protective gloves.

Installing the Synchronizer Hub with Locking Collar for 1st and 2nd Gears

Installation position:

• The low collar on the synchronizer hub - arrow A - faces 1st gear.

• The shoulder on the locking collar - arrow B - faces 1st gear and the chamfer faces 2nd gear.

Installing the Roller Bearing Inner Race

- Install the synchronizer rings, needle bearings and 1st gear wheel.

- Install the thrust washer - 1 -. The chamfer - arrow - faces the roller sleeve - 2 -.