5-speed manual gearbox 012/01W/0A9 — Dismantling and assembling pinion shaft from gearbox date 23 06 3 . — VW
5-speed manual gearbox 012/01W/0A9 — Dismantling and assembling pinion shaft from gearbox date 23 06 3 . on VW: 30 steps.
This page covers stripping and rebuilding the pinion shaft of the 012, 01W and 0A9 five-speed manual gearboxes on the platform codes listed below, from the gearbox build date shown in the title. The outer race is pulled with multi-purpose tool VW 771, the differential comes out, and the gears and synchro-hubs are pressed off the shaft in turn after each retaining ring is removed. The press pieces must bear only on the synchromeshed gear teeth, never on the dog teeth. On assembly the retaining rings are selected by fitting the thickest one that will still go in, and each synchro set, including the three-piece ring arrangements, is checked by pressing it onto its cone and measuring gap a with a feeler gauge. Parts being reused must be kept with their original gears.
🧭 Before you start
Pull the outer race, remove the differential, then press off the reverse gear inner race, 5th gear synchro-hub, 3rd gear wheel with 2nd gear, and the 1st gear synchro-hub, removing each retaining ring first. Check friction surfaces for scoring, measure the synchro-ring gaps with a feeler gauge, assemble the synchro sets with lugs in their notches, and fit the thickest retaining ring that will still go in at each position.
Fits: VW Passat B5 (3B)
- Special tools named: feeler gauge
- Renewed: if necessary
Don't miss
- Remove each retaining ring before pressing off the next part.
- Press only against synchromeshed gear teeth, never the dog teeth, or they are damaged.
- Fit the thickest retaining ring that will still go in.
- Check synchro friction surfaces for grooves and measure gap a with a feeler gauge.
- Reused synchro rings must stay matched to their original gears.
Written for this job from the workshop steps below · TorqFix editorial.
📋 Procedure
- Screw special tool VW 771/40 into pressure plate.
- Attach multi-purpose toolVW 771 and pull outer race out via pressure plate.
- Remove differential .
- Place thrust piece of fitting tool3128 below outer race.
- Assemble threaded spindle and thrust bearing of assembly tool3301 with thrust plateVW 401 on gearbox housing.
- Press off inner race with reverse gear synchromeshed gear.
- Remove retaining ring before pressing off.
- Press off synchro-hub with 5th gear synchromeshed gear.
- Remove retaining ring before pressing off.
- Remove retaining ring before pressing off. [Note: When pressing off parts, ensure that only teeth of synchromeshed gear (arrows) but not dog teeth contact splitter (A). Otherwise, the dog teeth will be damaged.]
- Press off 3rd gear wheel with 2nd gear synchromeshed gear.
- Remove retaining ring before pressing off.
- Press off synchro-hub with 1st gear synchromeshed gear.
- Remove retaining ring before pressing off.
- The outer race (A) must be fitted to press off the inner race.
- Determine thickest retaining ring which will still fit and install it.
- The retaining rings for the synchro-hubs and individual gear wheels should also be determined as shown for the tapered roller bearing. Available retaining rings and part numbers Electronic parts catalogue.
- The retaining rings for the synchro-hubs, needle bearings and individual gear wheels should be determined as shown in .
- Determine retaining rings as required from table. Part numbers Electronic parts catalogue. [Note: If components are not to be renewed, ensure that they are matched with their original gears.]
- Set inner ring (2) on synchromeshed gear (1).
- Set intermediate ring (3) in place. Lug (B) must be inserted in notch (A).
- Synchro-ring (4) is in place. Guide lugs (C) through notch (arrow).
- Check outer friction surface (arrow) for grooves or scoring and renew if necessary.
- Press inner ring onto cone of synchromeshed gear and measure gap "a" using a feeler gauge.
- Check inner friction surface of synchro-ring for grooves or scoring and renew if necessary.
- Press inner ring, intermediate ring and synchro-ring onto cone of synchromeshed gear and measure gap "a" using a feeler gauge.
- Insert locking pieces (arrows A) in installed synchro-hub (1).
- Set locking collar (2) over synchro-hub so that the wide tooth spacing of locking collar and synchro-hub (arrow B) align.
- Press synchro-ring into locking collar and measure gap (a) with a feeler gauge at positions (A),(B) and (C).
- Add measured values and divide by 3. [Note: The large internal diameter in tube2010 faces synchro-hub.]
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
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The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.