Dismantling and assembling output shaft for 1st through 4th gears — VW

🧭 Before you start

Fits: platform code 138

• Special tools named: feeler gauge
• Renewed: if necessary

Don't miss

• Allocate retaining rings using Electronic Parts Catalogue (ETKA).
• Pull off tapered roller bearing inner race on side facing clutch housing .
• Heat inner races of tapered roller bearings and synchro-hub with the inductive heaterVAS 6414 to approx. 100 °C and press them in to stop so there is no axial clearance.
• Fit locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
• Press on tapered roller bearing inner race .Determine retaining ring for tapered roller bearing inner race .

🔧 Engine codes this applies to

📋 Procedure

1. Support clutch housing with drift sleeve40-20 directly below bearing support.
2. Remove retaining ring for tapered roller bearing inner race on side facing clutch housing.
3. Insert press toolVW 431 into output shaft and place thrust plate40-105 on that.
4. Determine and install retaining ring .
5. Determine thickest retaining ring which will still fit and install it. [Note: Allocate retaining rings using Electronic Parts Catalogue.]

6. Fit shim under outer race.
7. Support gearbox housing with thrust piece2050 below bearing support. [Note: Pull off tapered roller bearing inner race on side facing clutch housing .]
8. First remove retaining ring.
9. Then, remove retaining ring and thrust washer .
10. After that, remove synchromeshed gear for 1st gear with synchro-rings.
11. Apply splitter(A) behind constant meshed teeth of synchromeshed gear for 1st gear. [Note: Heat inner races of tapered roller bearings and synchro-hub with the inductive heaterVAS 6414 to approx. 100 °C and press them in to stop so there is no axial clearance.]
12. Place inner ring (1) on cone of synchromeshed gear.
13. Press outer ring (2) on cone of inner ring. Measure gap size (a) at 3 points offset by 120° using feeler gauge.
14. Make a note of average value.
15. Check inner surface of synchro-ring (arrow) for scoring and radial contact scoring, renew if necessary.
16. Place inner ring, outer ring and synchro-ring on cone of inner ring.
17. Press on synchro-ring with outer ring whilst turning at same time in order to seat them.
18. Measure gap size (a) at 3 points offset by 120° using feeler gauge.
19. Make a note of average value.
20. Install synchromeshed gear for 2nd gear with needle bearing.
21. Place inner ring (A) on synchromeshed gear for 2nd gear.
22. Fit outer ring (B).
23. Fit synchro-ring (C).
24. Slide locking collar over synchro-hub.
25. Fit locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.
26. Install retaining ring.
27. Insert synchro-ring (A) in synchro-hub for 1st gear and 2nd gear.
28. Insert outer ring (B) into synchro-ring.
29. Insert inner ring (C) into outer ring.
30. Insert thrust washers for 1st and 4th gears into output shaft and .
31. Fit synchromeshed gear for 4th gear with needle bearing.
32. Press synchro-ring onto cone of synchromeshed gear and measure gap (a) using feeler gauge.
33. Place 4th gear synchro-ring on 4th synchromeshed gear.
34. Turn synchro-ring for 4th gear so that grooves align with locking pieces.
35. Install retaining ring.
36. Insert synchro-ring (A) in synchro-hub for 3rd gear and 4th gears.
37. Insert outer ring (B) into synchro-ring.
38. Insert inner ring (C) into outer ring. [Note: Press on tapered roller bearing inner race .Determine retaining ring for tapered roller bearing inner race .]

Other VW procedures

• Removing and installing mechatronic unit for dual clutch gearbox J743 (gearbox installed) · 7 torque figures
• Removing and installing turbocharger · 7 torque figures
• Adjusting differential – VW Sharan I / SEAT Alhambra · 10 torque figures
• Removing gearbox · 5 torque figures
• Removing and installing toothed belt, Golf 2004 ►, Golf 2009 ►, Golf Cabrio ►, Scirocco 2009 ► · 3 torque figures
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures