Dismantling and assembling drive pinion — VW

Reworking drive pinion

Rear driving shaft
Check for wear =>Page
34-103

Retaining ring for reverse gear
Always renew.

Reverse gear (at the drive pinion connection)
Check for wear =>Page
34-101

Thrust bolt
Front driving shaft
Check for wear =>Page
34-101

Woodruff key for synchro-hub
3rd gear needle bearing
Check for wear =>Page
34-101

3rd gear synchromeshed gear wheel
Release from drive pinion
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34-101
Paired with sprocket
Renew as pair only

3rd gear synchro-ring
Check for wear =>Page
34-102

Synchronizer body for 3rd and 4th gear
Release from drive pinion
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34-101
Check for wear =>Page
34-102

4th gear synchro-ring
Check for wear =>Page
34-102

Internal ring for needle bearing for 4th gear
Release from drive pinion
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34-101

4th gear needle bearing
4th gear synchromeshed gear wheel
Paired with sprocket
Renew as pair only

Thrust washer for 4th gear

Special tools and workshop equipment required

VW 401

VW 411
VW 435

VW 412
VW 419

Dismantling drive pinion

Remove thrust washer, synchromeshed gear wheel, needle bearing and synchro-ring for 4th gear.
Take interior ring for needle bearing for 4th gear, synchro-hub for 3rd and 4th gear and synchromeshed gear wheel for 3rd gear off drive pinion with VW straightening press and tools VW 401, VW 411 and VW 435.

1 -
VW 411
2 -
VW 435
3 -
VW 401

Remove 3rd gear needle bearing.
Dismantle synchro-hub for 3rd and 4th gears.

Check front drive pinion for wear

Check reverse gear splines for wear.
Check needle bearing sliding surfaces for wear.
Check sprockets for 1st and 2nd gear for damage and wear.
Fit front part of the drive pinion between two test prods and check needle bearing contact surface for 3rd gear for rough running.

Max. permissible deviation: 0.01 mm max.

If it is worn too much or the deviation is not permitted the front part of the drive pinion must be renewed. As the synchromeshed gear wheel must only be renewed as pair, the synchromeshed gear wheel for the 1st and the 2nd gear on the input gear must also be renewed.
Check needle bearing and synchromeshed gear wheel for 3rd and 4th gear for damage and wear. Renew synchromeshed gear wheels and input gear sprockets, if necessary.

Check all components of the synchro system for wear:

Clean synchro-ring inner cone with a wire brush.

Measure play between the front sprocket of the synchro rings and the corresponding sprocket with a feeler gauge or a comb gauge (prescribed play a = 1.1 mm). If the wear limit is achieved (a = 0.6 mm), renew synchro-ring. Synchro-rings wear early if the clutch is incorrectly adjusted or wrong operated.

1 -
4th gear synchromeshed gear wheel
2 -
Synchro-rings
3 -
3rd gear synchromeshed gear wheel

If a gear is constantly blocked despite of free clutch moving, it must be checked whether the synchro-ring has turned because of the notch lock wear in such a way that the gear rim teeth and the locking collar are facing each other and are not interlocking.
Check 4th gear thrust washer for wear.

Check rear drive pinion for wear

Check bush sockets for needle bearing in a banjo bolt for wear.
Check clutch plate splines and reverse gear for damage and wear.
Check seal contact surface for wear.
Check reverse gear for damage and wear, renew if necessary.

Installing

Observe following points when installing:

Install synchro-hub for 3rd and 4th gear for a short time.
Renew synchro-hub and locking collar as a pair only.

The groove of approx. 1 mm depth in the locking collar must show to the synchromeshed gear wheel for 4th gear when installing. The synchro-hub has only one chamfer to press the drive pinion in. It can be found on the side to the synchromeshed gear wheel for 3rd gear.
From November 1961 the synchro-hubs show to the centre lug. This improves the synchro-ring centralising on the synchro-hubs. Spare part number for the synchro-hub with the locking collar for 3rd and 4th gear: 311 311 307 A.

A -
= old version
B -
= new version

From March 1962 the circular step "a" of the synchro-rings was increased from 3 mm to 5 mm.

A -
= old version
B -
= new version

Fit woodruff key for synchro-hub to the drive pinion and set synchro-ring for 3rd gear onto the synchromeshed gear wheel cone.

Slide synchro-hub for 3rd and 4th gear onto the drive pinion with VW straightening press and tools VW 401, VW 412 and VW 419. When doing this slightly raise the synchromeshed gear wheel for 3rd gear and observe that the synchro-ring engages in the locks.

1 -
VW 412
2 -
VW 419
3 -
VW 401

Fit inner ring for needle bearing for 4th gear with VW straightening press and tools VW 401, VW 412 and VW 419.