Disassembly/Assembly of the Hollow Shaft

Disassembly/Assembly

Hollow Shaft Assembly:

Legend 1:

Legend 2:

- Refer to images for instructions and legends.

NOTE: Remove all components (No. 3 to 20) from hollow shaft by pressing off with suitable separating device (e.g. Kukko 15-17).

Assembly

NOTE: All components must be fitted onto hollow shaft dry to ensure that no oil penetrates between the contact surfaces.





- Fit driver dogs for synchronization with the lug pointing towards gearshift sleeve. It does not matter whether the lug points to the left or right.





- Check synchronizing disks by pressing onto the cones of the gear wheels and measuring gap "A" with a feeler gauge.
^ Installation dimension (new) = min. 1.1 mm
^ Wear limit = 0.6.-0.7 mm





A = Special Tool 9279
B = Inner bearing race

- Preload gear block onto the shaft with 5 ton. Use Special Tool 9279 for this.

Determining Size of Shim "s" for Hollow Shaft





- Determine basic value "G":
Constant value = 28.90 mm
Measured value = A
Basic value = G

- Slide hollow shaft in direction of arrow to the stop (facing surface of hollow shaft level with outer race of four-point bearing).
- Measure distance between collar of output shaft and inner race of cylindrical-roller bearing (dimension "A").
- Measured value "A" minus constant value 28.90 mm = Basic value "G".

Example
Measured value "A" 30.13 mm
Constant value - 28.90 mm
____________
Basic value "G" 1.23 mm

Determine Correction Value "K"





Constant value = 28.25 mm
Measured value = B
Bearing carrier = C
Inner bearing race = D





A = Pressure piece (e.g. VW 472/1)

- Measure distance between inner race and end of bearing carrier (dimension "B"). For this, insert four-point bearing with inner race into bearing carrier and hold in position with suitable pressing tool.
^ Deviations from the constant value, 28.25 mm gives the correction value "K".

NOTE: If the measured value "B" is less than 28.25 mm, the deviation must be added to basic value "G". If greater, the deviation must be subtracted from basic value "G".

- Determine thickness of shim "s":
Basic value "G", plus or minus correction value "K" gives the thickness of shim "s"

Example I
Basic value "G" 1.23 mm
Correction value "K" + 0.12 mm
__________
Thickness of shim "s" 1.35 mm

Example II
Basic value "G" 1.20 mm
Correction value "K" - 0.10 mm
__________
Thickness of shim "s" 1.10 mm