Dismantling and assembling output shaft: VW Polo 6C 1.8 (BBU)

🧭 Before you start

Fits: VW Polo 6C (2014–2017); platform code 121

• Special tools named: feeler gauge

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• Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
• Stop ring must be completely on tube2010.
• Pressing on tapered roller bearing inner race for bearing in gearbox housing

🔧 Engine codes this applies to

📐 44 workshop diagrams for BBU

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. First, remove retaining ring (A) for tapered roller bearing inner race.
2. Fit support railsVW 457 behind constant mesh teeth of synchromeshed gear for 1st gear (not dog teeth).
3. Note thrust washer for synchromeshed gear for 1st gear.
4. First, fit synchromeshed gear for 1st gear with thrust washer for synchromeshed gear for 1st gear.
5. Determine retaining ring for tapered roller bearing inner race (⇒ illustration on next page), and install it.

6. Determine thickest retaining ring which will still fit and install it.
7. Determine retaining ring from table. Part number Electronic Parts Catalogue
8. Remove retaining ring (A) for tapered roller bearing inner race.
9. Fit support railsVW 457 behind constant mesh teeth of synchromeshed gear for 1st gear (not dog teeth).
10. Press off synchromeshed gear for 1st gear together with tapered roller bearing inner race.
11. Remove thrust washer for synchromeshed gear for 1st gear.
12. Remove needle bearing for synchromeshed gear for 1st gear.
13. Remove synchro-ring for 1st gear.
14. Remove retaining ring for synchro-hub for 1st and 2nd gears.
15. Remove locking collar and synchro-hub for 1st and 2nd gears.
16. Remove synchromeshed gear for 2nd gear together with synchro-rings for 2nd gear.
17. Remove retaining ring for needle bearing.
18. Remove synchromeshed gear for 2nd gear.
19. Remove needle bearing for synchromeshed gear for 2nd gear.
20. Remove thrust washers for 2nd and 3rd gears with washer .
21. Remove synchromeshed gear for 3rd gear.
22. Remove synchro-ring for 3rd gear with needle bearing.
23. Remove retaining ring for synchro-hub and locking collar for 3rd and 4th gears.
24. Apply splitter(A) below synchro-ring for 4th gear.
25. Renew synchro-ring for 4th gear when assembling.
26. Remove synchro-ring for 4th gear.
27. Remove synchromeshed gear for 4th gear.
28. Remove retaining ring located above needle bearing for synchromeshed gear for 4th gear.
29. Remove needle bearing for synchromeshed gear for 4th gear.
30. Remove thrust washers for 4th and 5th gears, with washer .
31. Remove synchromeshed gear for 5th gear.
32. Remove needle bearing for synchromeshed gear for 5th gear.
33. Remove synchro-ring for 5th gear.
34. Remove retaining ring for locking collar and synchro-hub for 5th and reverse gears.
35. Remove locking collar and synchro-hub for 5th and reverse gears.
36. Press synchro-ring onto cone of synchromeshed gear and measure gap (a) using feeler gauge.
37. Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap (a) using a feeler gauge.
38. Slide locking collar over synchro-hub.
39. Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
40. Slide locking collar over synchro-hub.
41. Insert locking pieces (2), and install springs (1) offset by 120 degrees.
42. Install stop ring (5).
43. Press tube2010 into stop ring of synchro-hub. In the process, lever stop ring on alternating sides out of synchro-hub.
44. Stop ring must be completely on tube2010.
45. Remove stop ring together with tube2010.
46. Insert stop ring together with tube2010 into synchro-hub with locking collar for 5th gear.
47. Remove tube2010, making sure that the lugs (arrow) engage in the synchro-hub.
48. Fit locking collar and synchro-hub for 5th and reverse gears.
49. Install retaining ring.
50. Insert synchro-ring for 5th gear.
51. Install 5th gear synchromeshed gear with needle bearing.
52. Install thrust washers for 4th and 5th gears and .
53. Install synchromeshed gear for 4th gear with needle bearing.
54. Install retaining ring.
55. Fit synchro-ring for 4th gear.
56. Install retaining ring.
57. Insert synchro-ring for 3rd gear.
58. Fit synchromeshed gear for 3rd gear with needle bearing.
59. Install thrust washers for 2nd and 3rd gears and .
60. Install 2nd gear synchromeshed gear with needle bearing.

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