Dismantling and assembling output shaft for 3rd and 4th gear — VW

🧭 Before you start

Fits: VW Sharan II / SEAT Alhambra (7N, 2010–), VW Tiguan I (5N, 2007–2016)

• Special tools named: puller, feeler gauge

Don't miss

• If 5th gear wheel is close to circumferential groove for retaining ring (arrow) during pressing procedure, secure output shaft from falling.
• When 5th gear wheel has been pressed off in previous step, let output shaft cool off.
• Pull off tapered roller bearing inner race for bearing in gearbox housing .

📋 Procedure

1. Before fitting puller, position press toolVW 431 in output shaft and set thrust plate40-105 on it.
2. Remove retaining ring.
3. Place tools beneath 3rd gear synchromeshed gear so that no parts will be damaged during pressing. [Note: If 5th gear wheel is close to circumferential groove for retaining ring (arrow) during pressing procedure, secure output shaft from falling.]
4. Remove retaining ring.
5. Press inner ring onto cone of synchromeshed gear and measure gap (a) using a feeler gauge.

6. Press synchro-ring, outer ring and inner ring onto cone of synchromeshed gear and measure gap (a) using a feeler gauge.
7. Install synchromeshed gear for 4th gear with needle bearing.
8. Place inner ring (A) on 4th gear synchromeshed gear.
9. Fit outer ring (B).
10. Fit synchro-ring (C).
11. To dismantle, remove springs (1).
12. To assemble, slide locking collar over synchro-hub.
13. Insert locking pieces and install springs offset 120°.
14. Install retaining ring.
15. Install synchromeshed gear for 3rd gear with needle bearing.
16. Heat gear wheel for 5th gear to approx. 150° C.
17. Press on gear wheel quickly so that heat is not immediately transferred to output shaft.
18. Heat gear wheel for 6th gear to approx. 150° C.
19. Fit retaining ring. [Note: When 5th gear wheel has been pressed off in previous step, let output shaft cool off.]
20. Press on gear wheel quickly so that heat is not immediately transferred to output shaft.
21. Insert locking device for gear wheel for 6th gear. [Note: Pull off tapered roller bearing inner race for bearing in gearbox housing .]
22. Place new shim with previous value under outer race.
23. Before setting up pulling device, set thrust plate30-11 on output shaft.
24. Place new shim with previous value under outer race.
25. Support clutch housing with tubeVW 415 A directly below bearing support.

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