Assembling "“output shaft 1”" — VW

🧭 Before you start

Fits: platform code XXX

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• Make sure that cage is not broken.
• Put on locking collar with synchro-hub. Make sure groove for selector fork is pointing »upwards«, and collar of locking collar »downwards«.
• Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!

📋 Procedure

1. Place needle bearing onto output shaft.
2. Make sure that cage is not broken.
3. Wet bearing with oil.
4. Fit synchromeshed gear for 2nd gear over needle bearing.
5. Wet friction surfaces with oil.

6. Place both synchro-rings with outer ring on synchromeshed gear for 2nd gear.
7. Put on locking collar with synchro-hub. Make sure groove for selector fork is pointing »upwards«, and collar of locking collar »downwards«.
8. Press on synchro-hub. [Note: Bear two things in mind when pressing:Lift and turn synchromeshed gear for 2nd gear. This allows the synchro-ring to locate its installation position before it is clamped by the synchro-hub.Once the synchro-ring has found its seat, continue pressing only until an increased force is felt. Then stop pressing immediately. Synchromeshed gear for 2nd gear must have axial play. Synchromeshed gear has reached its installation position as soon as force during pressing rises. Continuing to press will force synchro-hub against needle bearing and damage it.]
9. Press on sleeve for needle bearing of synchromeshed gear for 4th gear. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!]
10. Fit needle bearing.
11. Moisten needle bearing with oil.
12. Wet friction surfaces with oil.
13. Put on large synchro-ring, outer ring and small synchro-ring.
14. Put on synchromeshed gear for 4th gear.
15. Press on washer. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!After pressing, synchromeshed gear must turn »freely« when shaft is in horizontal position.Output shaft is assembled as far as this washer for purpose of adjusting shaft.]
16. ⚠ Do not assemble the output shaft further until the gearbox has been adjusted Determining shims. — Press on sleeve for needle bearing of synchromeshed gear for 3rd gear. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!]
17. Fit needle bearing.
18. Moisten needle bearing and friction surfaces with oil.
19. Put on synchromeshed gear for 3rd gear, small synchro-ring, outer ring and large synchro-ring.
20. Press on locking collar and synchro-hub. [Note: Bear two things in mind when pressing:Lift and turn synchromeshed gear for 3rd gear. This allows synchro-ring to locate its installation position before ring is clamped by synchro-hub.Once the synchro-ring has found its seat, continue pressing only until an increased force is felt. Then stop pressing immediately. Synchromeshed gear for 3rd gear must have axial play. Synchromeshed gear has reached its installation position as soon as force during pressing rises. Continuing to press will force synchro-hub against needle bearing and damage it.]
21. Press on sleeve for needle bearing of synchromeshed gear for 1st gear. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!]
22. Fit needle bearing.
23. Moisten needle bearing and friction surfaces with oil.
24. First place small synchro-ring onto synchromeshed gear for 1st gear.
25. Then outer ring and then large synchro-ring.
26. Press on washer. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!]
27. Press on tapered roller bearing inner race. [Note: Here also stop pressing immediately when you notice a rise in force during pressing. Do not re-press!]
28. Wet bearing with oil.
29. Tighten new bolt.

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