35593750 Disassembling and assembling the output shaft

WM 355937 Disassembling and assembling the output 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 output shaft

Removing output shaft





Overview of output shaft









Removal instructions for output 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

When replacing the taper roller bearings, determine the installation position before removing the output shaft (actual measurement -> 390815 Adjusting drive set Adjustments).

1. Use the outer bearing ring -A- to press off the taper roller bearing.





Taper roller bearing

Assembling the output shaft





Overview of output shaft









Assembly instructions for output shaft

Information

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

1. Check triple-cone synchronisation (1st gear) for wear. To do this, press the friction ring, cone ring and synchroniser ring onto the gear wheel and measure the gap dimension with a feeler gauge.





Check synchronisation.





2. Check double-cone synchronisation (2nd gear) for wear. To do this, press the friction ring and synchroniser ring firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.





Check synchronisation.





3. Check single-cone synchronisation 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

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





Inserting spring

5. Install operating sleeves in correct position. The slanted side -1- is facing the loose gear wheel for reverse gear in the case of the operating sleeve for 5th and reverse gear. The slanted side is facing the loose gear wheel for 2nd gear in the case of the operating sleeve for 1st and 2nd gear.





Operating sleeve

6. Determine the circlip for the taper roller bearing. To do this, determine the thickest ring that can still be used.





Inserting circlip

7. Determine the other circlips in the same way.

Information

The thickness of circlips 1, 2, 4, 5 and 7 must be calculated again. Circlips 3 and 6 always have the same thickness. Circlip 3 is 2.5 mm and circlip 6 is 2.0 mm thick.

Arrangement of the circlips:





Circlips for output shaft

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