6-speed manual gearbox 01E, four-wheel drive — Dismantling and assembling pinion shaft and hollow shaft — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

Don't miss

• Part number allocation Electronic parts catalogue "“ETKA”"
• Do not press off together with 1st and 2nd gear synchro-hub and 2nd gear synchromeshed gear.
• Do not press off together with 1st gear synchromeshed gear and inner race for small tapered roller bearing.
• Position tubeVW 415 A with shoulder towards synchro-hub.Position thrust pad3118 with stepped shoulder towards press toolVW 412.

📋 Procedure

1. Heat gearbox housing in area of bearing seat for approx. 15 minutes to approx. 100 °C with a hot air blower.
2. Insert outer race in heated gearbox housing and press using workshop press until heat exchange has taken place.
3. Heat inner race to approx. 100 °C and fit.
4. Press home with no axial play.
5. Determine thickest retaining ring which will still fit.

6. Determine retaining ring from table. [Note: Part number allocation Electronic parts catalogue
7. Fit retaining ring. [Note: Do not press off together with 1st and 2nd gear synchro-hub and 2nd gear synchromeshed gear.]
8. Oil needle bearing.
9. Install retaining ring, shim for 1st gear synchromeshed gear, synchro-ring for 1st gear, and 1st gear synchromeshed gear with spring and needle bearing.
10. Heat inner race to approx. 100 °C and fit.
11. Press home with no axial play. [Note: With shoulder of thrust piece3118 facing downwards, press only onto bearing inner race.Position stepped shoulder of tubeVW 415 A facing up towards press toolVW 412.After pressing on, check axial clearance of 1st gear synchromeshed gear.]
12. To remove, first remove shim (A) then retaining ring (B).
13. To install, fit retaining ring (B) then shim (A).
14. Remove locking collar for 1st and 2nd gear and synchro-ring for 1st gear.
15. Remove shim and retaining ring for synchro-hub.
16. Press off 2nd gear synchromeshed gear with synchro-hub for 1st and 2nd gear. [Note: Do not press off together with 1st gear synchromeshed gear and inner race for small tapered roller bearing.]
17. Fit needle bearing, synchromeshed gear with spring and synchro-ring for 2nd gear.
18. Oil needle bearing.
19. Heat synchro-hub to approx. 100 °C and fit.
20. Press home with no axial play. [Note: Position tubeVW 415 A with shoulder towards synchro-hub.Position thrust pad3118 with stepped shoulder towards press toolVW 412.]
21. Determine thickest retaining ring which will still fit.
22. Determine retaining ring from table. [Note: Part number allocation Electronic parts catalogue
23. Fit retaining ring in direction of arrow on synchro-hub.
24. Lay shim S4 behind bearing seat in bearing plate.
25. Position thrust pad3062 with stepped shoulder towards press toolVW 407.
26. Press on outer race for small tapered roller bearing to stop.

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