Disassembling and Assembling the Output Shaft

Disassembling and assembling the output shaft
Tools








Preliminary work

1. Remove transmission.





2. Tighten the transmission using engine support 9589 or engine and gear support VW 540 at the assembly support.
3. Drain transmission oil.
4. Disassemble the transmission.

Disassembling the output shaft
Removing output shaft











Removal instructions for output shaft

Note: 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.

Note: When replacing the taper roller bearings, determine the installation position before removing the output shaft (actual measurement).





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

Assembling the output shaft














Assembly instructions for output shaft

Note: 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.
Installation dimension (new): 1.4 to 2.0 mm
Wear dimension: 0.6 mm





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.
Installation dimension (new): 1.4 to 2.0 mm
Wear dimension: 0.6 mm
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.









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





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.





6. Determine the circlip for the taper roller bearing. To do this, determine the thickest ring that can still be used.
7. Determine the other circlips in the same way.

Note: The thickness of circlips 1, 2, 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:

Subsequent work

1. Assemble transmission.
2. Fill with transmission oil.
3. Remove transmission from assembly support.
4. Install transmission.