Output Shaft, Disassembling And Assembling

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Special tools and workshop equipment required 

• Bearing Installer - Differential Bearing :40-21 
• Press Piece - Trailing Arm :2010 
• Inductive Heater :VAS 6414 
• Press Plate :VW402 
• Press Piece - Multiple Use :VW412 
• Press Piece - Multiple Use :VW519 

Special tools and workshop equipment required 

• Press Piece - 37mm :VW416B 
  Fig 1: Press Piece - 37mm VW416 B

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• Press Piece - 60mm :VW415A 
  Fig 2: Identifying Press Piece

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• Press Piece - Multiple Use :VW429 
  Fig 3: Press Piece - Multiple Use VW429

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• Press Piece - Bushing :3118 

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Disassembling

• Gear set, disassembled. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .

Press out the output shaft 1, vehicles without self-locking center differential

2 -  Press Plate :VW402 

3 -  Press Piece - Multiple Use :VW412 

Press out the output shaft 1, vehicles with self-locking center differential

2 -  Press Plate :VW402 

3 -  Press Piece - Multiple Use :VW412 

4 -  Press Piece - 37mm :VW416B 

Continuation for all vehicles

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The following components can now be removed:

1. 6th Gear
2. Thrust Washer
3. 2nd Gear Assembly
4. Needle Bearing
5. Inner Race/Needle Bearing

-- Switch the gearshift rail/shift fork for the 2nd and reverse gear -1- in the -direction of the arrow A-.

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-- Remove the synchronization for the 2nd and reverse gear -2- with all individual parts out of the shift fork -1- in the -direction of the arrow B-.

-- Turn the gearshift rail/shift fork for the 2nd and reverse gear -1- slightly to the side and remove it from the bearing bracket.

The following components can now be removed:

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1. Reverse Gear Assembly
2. Needle Bearing
3. Inner Race/Needle Bearing
4. Thrust Washer

-- Remove the bearing bracket with the shift fork -1- in the -direction of the arrow- from the synchronization -3-.

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The following components can now be removed:

2 -  1st Gear Assembly with: Thrust Washer, Needle Bearing, Inner Race/Needle Bearing

3 -  Synchronization for 1st Gear Assembly / 3rd Gear Assembly with All Individual Parts

4 -  3rd Gear Assembly with the Needle Bearing

Assembling

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-- Position the needle bearing -1-, 3rd gear assembly -2- and synchronizer rings -3-.

Pay attention to the installation position of the synchronizer rings. Refer to Figure.

Synchronizer hub for 1st gear assembly / 3rd gear assembly 2, pressing on

• Warm the synchronizer hub -2- using the Inductive Heater :VAS 6414  to 100 °C (212 °F).
• The lettered side of the synchronizer hub points to the Press Piece - Lower Ball Joint :3146  -3-.

1 -  Press Plate :VW402 

3 -  Press Piece - Lower Ball Joint :3146 

4 -  Press Piece - Bushing :3118 

5 -  Press Piece - 60mm :VW415A 

6 -  Press Piece - Trailing Arm :2010  (Only on Vehicles with Self-Locking Center Differential)

7 -  Press Piece - Multiple Use :VW412 

-- Lift the 3rd gear synchronizer ring -8- with 3rd gear assembly -9- slightly, until the anti-twist mechanism -arrow B- of the synchronization is flush with the cut-outs -arrow A- of the synchronizer hub -2-.

-- Insert the three thrust pieces -arrows-.

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-- Push the double-toothed locking collar onto the opening -arrow A- with the lettering facing upward.

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-- Press the tops of the thrust pieces in slightly by hand when installing.

Inner Race Needle Bearing 1 for 1st Gear Assembly, Installing

• Layout of the oil filler hole -arrows- at an offset of approximately 90°.
• Installation position: the lettering on the bearing -1- (thicker wall thickness) points to the Press Piece - Multiple Use :VW429  .

2 -  Press Piece - Multiple Use :VW429 

3 -  Press Piece - 60mm :VW415A 

4 -  Press Piece - Bushing :3118 

5 -  Press Piece - Multiple Use :VW519  (Only on Vehicles with Self-Locking Center Differential)

-- Position the synchronizer rings for 1st gear -1-, needle bearing for 1st gear assembly -2-, and 1st gear assembly -3- and the thrust washer -4-.

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Tip:

• The illustration shows a similar gear assembly!
• Pay attention to the installation position of the synchronizer rings -arrow-. Refer to Figure.

-- Press out the locking sleeves for the 1st and 3rd gear -1- and the 2nd and reverse gear -2- out of the bearing bracket. Refer to Figure.

Bearing bracket 3, pressing on

• Insert the shift fork for 1st and 3rd gear -1- in the locking collar for 1st and 3rd gear -2-.
• Then pressing on the gearshift rail for the 1st and 3rd gear -arrow- guide in the bearing bracket -3-.

4 -  Press Piece - 60mm :VW415A 

5 -  Press Piece - Multiple Use :VW429 

6 -  Press Piece - Multiple Use :VW519 

Needle bearing inner race 2 for the reverse gear assembly

• Position the thrust washer -1- beforehand.
• Layout of the oil filler hole -arrows- at an offset of approximately 90°.
• Installation position: the lettering on the bearing -2- (thicker wall thickness) points to the Press Piece - Multiple Use :VW519  .

3 -  Press Piece - Multiple Use :VW519 

4 -  Press Piece - Multiple Use :VW429 

5 -  Press Piece - 60mm :VW415A 

-- Position the reverse gear assembly needle bearing -1- and reverse gear assembly -2- and synchronizer ring -3-.

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Synchronizer hub for the 2nd gear assembly / reverse gear assembly 1, pressing on

• Warm the synchronizer hub -1- using the Inductive Heater :VAS 6414  to 100 °C (212 °F).
• The lettered side of the synchronizer hub points to the Press Piece - Bushing :3118  .

-- Lift the reverse gear synchronizer ring -6- with reverse gear assembly -5- slightly, until the anti-twist mechanism -arrow B- of the synchronization is flush with the cut-outs -arrow A- of the synchronizer hub -1-.

2 -  Press Piece - Bushing :3118 

3 -  Press Piece - Multiple Use :VW519 

4 -  Bearing Installer - Differential Bearing :40-21  (Only on vehicles without self-locking center differential)

-- Insert the three thrust pieces -arrows-.

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-- Insert the shift fork for the 2nd gear / reverse gear -1- in the locking collar for the 2nd gear / reverse gear -2-.

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-- Guide in the shift fork with the locking collar for the 2nd gear / reverse gear in the bearing bracket -arrow A-.

• The bevel of the locking collar -arrow- points to the 2nd gear assembly

-- Press on the double-toothed locking collar on the cut-out -arrow A-.

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-- Press the tops of the thrust pieces in slightly by hand when installing.

Needle Bearing Inner Race 1, 2nd Gear Wheel, Installing

• Layout of the oil filler hole -arrows- at an offset of approximately 90°.
• Installation position: the lettering on the bearing -2- (thicker wall thickness) points to the Press Piece - Multiple Use :VW519  .

2 -  Press Piece - Multiple Use :VW519 

3 -  Bearing Installer - Differential Bearing :40-21  (Only on vehicles without self-locking center differential)

-- Press on the synchronizer rings for 2nd gear -1-, needle bearing for 2nd gear assembly -2-, and 2nd gear assembly -3- and the thrust washer -4-.

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• The illustration shows a similar gear assembly!
• Pay attention to the installation position of the synchronizer rings -arrow-. Refer to Figure.

Installing the 6th gear 1

• Warm the 6th gear using the Inductive Heater :VAS 6414  to 120 °C (248 °F).

2 -  Press Piece - Multiple Use :VW519 

3 -  Bearing Installer - Differential Bearing :40-21  (Only on vehicles without self-locking center differential)

-- Assemble the gear set. Refer to GEAR SET, DISASSEMBLING AND ASSEMBLING .