Assembling layshaft — VW

Assembling layshaft
Note
Lubricate all needle bearings and synchro-rings with gear oil before installing.
Always press on needle bearing inner race, synchro-hubs and gear wheels as far as stop, so that the synchromeshed gears have the prescribed axial play.
If components are not to be renewed, ensure that they are matched with their original gears.
Checking synchro-rings for 5th and 6th gear for wear
Press synchro-ring onto cone of synchromeshed gear and measure gap
a
using
feeler gauge
.
Gap
a
Wear limit
5th and 6th gears
0.5 mm
Assembly and installation position of locking collar/synchro-hub for 5th and 6th gear
Slide locking collar
1
over synchro-hub
2
.
The peripheral groove
arrow A
on the locking collar and the high collar
arrow B
of the synchro-hub must face towards the synchromeshed gear for 6th gear.
The centre recess
arrow D
in the locking collar and the recesses for the thrust pieces
3
in the synchro-hub must be aligned.
Insert thrust pieces
3
in
direction of arrow C
.
Turn locking collar/synchro-hub for 5th and 6th gear so that the side of the 5th gear faces upwards.
Engage lugs of spacer
A
in recesses
arrows
of synchro-hub.
Fit synchromeshed gear for 5th gear together with synchro-ring for 5th gear on locking collar/synchro-hub.
Secure locking collar with
assembly clip
T50030/2
.
Note
To ensure that the
assembly clip
T50030/2
has sufficient clamping force also fit synchro-ring for 6th gear
B
.
Before and after pressing on, ensure that the spacer
A
is engaged in the recesses in the synchro-hub.
Place secured unit together with needle bearing onto layshaft.
Press secured unit onto layshaft as far as stop.
Note
Make sure that the splines of the synchro-hub and the layshaft mesh properly when installing.
Remove
assembly clip
T50030/2
.
Press on needle bearing inner race
A
for synchromeshed gear of 6th gear as far as stop.
Fit needle bearing and synchromeshed gear for 6th gear.
Heat gear wheel for 3rd gear to max. 140°C, and press it on as far as stop.
Installation position: high inside collar faces constant mesh gear.
WARNING
Wear protective gloves!
Press on gear wheel quickly so that heat is not immediately transferred to layshaft.
Note
Check synchro-rings for 5th and 6th gear for axial clearance.
Heat constant mesh gear to max. 140°C, and press it on as far as stop.
Installation position: high inside collar faces towards gear wheel for 3rd gear.
WARNING
Wear protective gloves!
Press on gear wheel quickly so that heat is not immediately transferred to layshaft.
Insert new retaining ring
Item
.
Push oil guide ring
1
onto splines as far as dimension
a
of approx. 28 mm.