35403750 Disassembling and assembling the drive shaft

WM 354037 Disassembling and assembling the drive shaft

Tools





Preliminary work

1. Remove transmission. -> 343519 Removing and installing transmission - section on "Removing" 34351903 Removing and installing transmission
2. Tighten the transmission using engine support 9589 or engine and gear support VW 540 at the assembly support.





Transmission on assembly support

3. Drain transmission oil. -> 340155 Changing transmission oil - section on "Draining" Removal and Replacement
4. Disassemble the transmission. -> 343537 Disassembling and assembling transmission - section on "Disassembling" 34353750 Disassembling and assembling transmission

Disassembling the drive shaft

Removing drive shaft





Overview of drive shaft





Removal instructions for drive shaft

Information

Circlips of different sizes and thicknesses are used. For this reason, the individual circlips must be marked (e.g. with numbers). The thickness of the circlip must be determined again if a directly affected component is replaced.

1. Press off fixed gear wheel for 5th gear -as shown in illustration-.





Pressing off gear wheel

2. Press synchroniser ring for 3rd gear -Arrow- to the loose gear wheel for 3rd gear.





Pressing off synchronising hub

3. Press off synchronising hub for 3rd and 4th gear -as shown in illustration-.

Assembling the drive shaft

Fitting drive shaft





Overview of drive shaft





Assembly instructions for drive shaft

Information

Circlips of different sizes and thicknesses are used. For this reason, the individual circlips must be marked (e.g. with numbers). The thickness of the circlip must be determined again if a directly affected component is replaced.

Information

All transmission parts, particularly synchronisation parts, must always be coated with transmission oil before assembly. Avoid assembling dry parts.

1. Check the synchroniser rings for wear.
- Push ring into shift sleeve.
- Measure gap dimension -a- with a feeler gauge in positions -A, B and C-.
- Add up the measured values and divide by three. The value obtained must not be less than 0.5 mm.





Checking synchronisation

2. Insert the spring into the loose gear wheel so that the angled end engages in the bore.





Inserting spring

3. Fit operating sleeve so that the slant -1- is facing 4th gear and the offset side -2- is facing 3rd gear.





Operating sleeve

4. Determine the circlip for 4th gear. To do this, determine the thickest ring that can still be used.





Determining circlip

5. Determine the circlip for 5th gear in the same way as for 4th gear.
6. Heat the synchronising hubs for 3rd and 4th gear to approx. 100 °C and press onto the drive shaft. The high collar is facing the loose gear wheel for 3rd gear.





Pressing on synchronising hub

7. Heat the fixed gear wheel for 5th gear to approx. 100 °C and press onto the drive shaft. The high collar is facing reverse gear and the oil pockets are facing 4th gear.





Pressing on fixed gear wheel

Subsequent work

1. Assemble transmission. -> 343537 Disassembling and assembling transmission - section on "Assembling" 34353750 Disassembling and assembling transmission
2. Fill with transmission oil. -> 340155 Changing transmission oil - section on "Filling" Removal and Replacement
3. Remove transmission from assembly support.
4. Install transmission. -> 343519 Removing and installing transmission - section on "Installing" 34351903 Removing and installing transmission