Dismantling and assembling pinion shaft and hollow shaft from gearbox date 23 06 3 — VW

VW
Passat
1997
Passat Variant
1997
Power transmission
5-speed manual gearbox 01A, all-wheel drive
Edition
03.2011
Dismantling and assembling pinion shaft and hollow shaft from gearbox date 23 06 3
Special tools and workshop equipment required
Pressure plate
VW 401
Pressure plate
VW 402
Press tool
VW 407
Press tool
VW 411
Press tool
VW 412
Tube
VW 415 A
Tube
VW 416 B
Tube
VW 418 A
Thrust ring
VW 429
Thrust pad
VW 447 i
Thrust piece
VW 454
Tube
VW 519
Multipurpose tool
VW 771
Support
40 - 103
Tube
2010
Thrust pad
3062
Fitting tool
3128
Splitter
Kukko 17/2
Internal puller
Kukko 21/1
Note
From gearbox date 23 06 3, a new 3-part synchronisation for 1st gear and a 2-part synchronisation for 2nd gear as well as synchro-rings with enlarged cones and a reduction in dog teeth for 5th and reverse gear were introduced. The synchromeshed gears, locking collars and synchro-hubs were modified accordingly and cannot be installed mixed with synchronising parts of the old design.
When installing new gear wheels or a final drive gear set, consult technical data
Chapter
and
Electronic parts catalogue
.
Adjustments are required when components marked
1
) are renewed. Adjustment overview
Chapter
.
Gearbox housing
Shim
„S3“
Adjustment overview
Chapter
Double tapered roller bearing outer race
1)
Pulling out
Fig.
Pressing in
Fig.
Pinion shaft
1)
Is paired with crown wheel. Always renew together as a set.
Adjusting drive pinion and crown wheel
Chapter
.
Double tapered roller bearing inner race
1)
Will be damaged when removed
Renew
Pressing off
Fig.
Pressing on
Fig.
Retaining ring
Redetermine thickness if double tapered roller bearing is renewed
Fig.
.
Needle bearing
For pinion shaft in hollow shaft.
Lubricate with
grease
MoS2
.
Hollow shaft
1)
Determine according to
Electronic parts catalogue
.
Needle bearing for 1st gear
Needle bearing for 1st gear
Synchromeshed gear for 1st gear
Inner ring for 1st gear
Installation position
Fig.
Check for wear
Fig.
Renew if scored
Intermediate ring for 1st gear
Installation position
Fig.
Check for wear
Fig.
Synchro-ring for 1st gear
Installation position
Fig.
Check for wear
Fig.
Renew if scored
Locking collar for 1st and 2nd gears
Mark installation position
Assembling locking collar and synchro-hub
Fig.
Thrust piece
Installing locking pieces (Qty. 3)
Fig.
Synchro-hub for 1st and 2nd gears
Pressing off
Fig.
Pressing on
Fig.
Assembling locking collar and synchro-hub
Fig.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 1
.
If synchro-hub or hollow shaft is replaced, redetermine thickness
Fig.
.
Needle bearing
For 2nd gear
Synchro-ring for 2nd gear
Installation position
Fig.
Check for wear
Fig.
Renew if scored
Intermediate ring for 2nd gear
Installation position
Fig.
Check for wear
Fig.
Inner ring for 2nd gear
Installation position
Fig.
Check for wear
Fig.
Renew if scored
Synchromeshed gear for 2nd gear
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 2
.
Gear wheel for 3rd gear
Pressing off
Fig.
Groove faces 4th gear.
Pressing on
Fig.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 3
.
If 3rd gear wheel or hollow shaft is renewed, redetermine thickness
Fig.
.
Gear wheel for 4th gear
Pressing off
Fig.
Collar faces 3rd gear
Pressing on
Fig.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 4
.
If 4th gear wheel or hollow shaft is renewed, redetermine thickness
Fig.
.
Needle bearing
Synchromeshed gear for 5th gear
Modified features
Fig.
.
Spring
Modified features
Fig.
.
Insert in 5th gear synchromeshed gear
Fig.
.
Allocation to synchromeshed gear
Electronic parts catalogue
.
Synchro-ring for 5th gear
Modified features
Fig.
.
Check for wear
Fig.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 5
.
Synchro-hub for 5th gear and reverse gear
Modified features
Fig.
.
Pressing off
Fig.
Pressing on
Fig.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 6
.
If synchro-hub or hollow shaft is replaced, redetermine thickness
Fig.
.
Needle bearing
For reverse gear
Locking collar for 5th and reverse gear
Modified features
Fig.
.
Installation position: groove faces 5th gear
Fig.
.
Reverse gear synchro-ring
Modified features
Fig.
.
Check for wear
Fig.
Spring
Modified features
Fig.
.
Insert in reverse gear synchromeshed gear
Fig.
.
Allocation to synchromeshed gear
Electronic parts catalogue
.
Synchromeshed gear for reverse gear
Modified features
Fig.
.
Retaining ring
Mark for identification.
Installation position
Fig.
,
item 7
.
Tapered roller bearing inner race
1)
Pressing off
Fig.
Pressing on
Fig.
Bush
To secure small tapered roller bearing outer race.
Pulling out
Fig.
Need not be fitted after small tapered roller bearing has been renewed.
Tapered roller bearing outer race
1)
Pressing out
Fig.
Pressing in
Fig.
Shim
„S
4
“
Adjustment overview
Chapter
Ring
Holds rubber washer.
Determine according to
Electronic parts catalogue
.
Rubber washer
For length compensation
Determine according to
Electronic parts catalogue
.
Gearbox cover
Thinly coat sealing surfaces with
sealing paste
AMV 188 001 02
.
Modified synchronisation of 5th and reverse gear from gearbox date 23 06 3
Note
Parts of old design through gearbox date 22 06 3 and parts from new design from gearbox date 23 06 3 cannot be installed together.
Following components were modified:
Synchromeshed gear for 5th gear
Synchro-spring
Synchro-ring for 5th gear
Synchro-hub for 5th and reverse gear
Locking collar for 5th and reverse gear
Synchro-ring for reverse gear
Synchro-spring
Reverse gear synchromeshed gear
Scope of modification:
Reduction in dog teeth of synchromesh mechanism
arrows A
Synchro-rings with enlarged cones
arrows B
Pulling out double tapered roller bearing outer race
Remove differential
Chapter
.
Place thrust piece of
fitting tool
3128
below outer race.
Fit threaded part of
fitting tool
3128
with
thrust plate
VW 401
onto gearbox housing.
As nut arrow is tightened, outer race is pulled out of housing.
Pressing in double tapered roller bearing outer race
The smaller diameter of the
thrust pad
3062
faces outer race.
Pressing off double tapered roller bearing inner race
Remove retaining ring before pressing off.
The outer race
A
must be fitted to press off the inner race.
Pressing on double tapered roller bearing inner race
Determining thickness of retaining ring
Determine thickest retaining ring which will still fit and install it.
Note
Retaining rings for the synchro-hubs and individual gear wheels should also be determined as shown for the double tapered roller bearing.
Available retaining rings and part numbers
Electronic parts catalogue
.
Pulling out securing bush for tapered roller bearing outer race
A
Internal puller, 12…14.5 mm
, e.g.
Kukko 21/1
Pressing out tapered roller bearing outer race
The outer race is pressed out together with ring
Item
, shim
„S
4
“
Item
and rubber washer for length compensation
Item
.
Pressing in tapered roller bearing outer race
Pressing off tapered roller bearing inner race
Press off inner race with reverse gear synchromeshed gear.
A
Splitter, 22 … 115 mm
, e.g.
Kukko 17/2
Pressing on tapered roller bearing inner race
Fit retaining ring before pressing on inner race.
Pressing off synchro-hub for 5th gear and reverse gear
Remove retaining ring before pressing off.
Press off synchro-hub with 5th gear synchromeshed gear.
A
Splitter, 22 … 115 mm
, e.g.
Kukko 17/2
Pressing off gear wheel for 4th gear
Remove retaining ring before pressing off.
Pressing off gear wheel for 3rd gear
Remove retaining ring before pressing off.
Note
When pressing off parts, ensure that only teeth of synchromeshed gear
arrows
but not dog teeth contact splitter
A
. Otherwise, the dog teeth will be damaged.
Press off 3rd gear wheel with 2nd gear synchromeshed gear.
A
Splitter, 22 … 115 mm
, e.g.
Kukko 17/2
Pressing off synchro hub for 1st and 2nd gear
Remove retaining ring before pressing off.
Press off synchro-hub with 1st gear synchromeshed gear.
Position of retaining rings
The retaining rings for the synchro-hubs, needle bearings and individual gear wheels should be determined as shown in
Fig.
.
The retaining ring
1
secures the synchro-hub for 1st and 2nd gear.
Identification: blue colour
Retaining ring thickness (mm)
1.90
1.96
2.02
1.93
1.99
Retaining ring
2
secures the needle bearing for 2nd gear synchromeshed gear.
Identification: blue colour
Retaining ring thickness (mm)
2.50
Retaining ring
3
secures the 3rd gear wheel.
Retaining ring thickness (mm)
1.90
1.98
2.06
1.94
2.02
Retaining ring
4
secures the 4th gear wheel.
Retaining ring thickness (mm)
1.86
1.94
1.90
1.98
Retaining ring
5
secures the needle bearing for 5th gear synchromeshed gear.
Identification: brown colour
Retaining ring thickness (mm)
2.00
Retaining ring
6
secures the synchro-hub for 5th and reverse gear.
Identification: blue colour
Retaining ring thickness (mm)
1.90
1.96
2.02
1.93
1.99
2.05
Retaining ring
7
secures needle bearing for reverse gear synchromeshed gear.
Retaining ring thickness (mm)
2.50
Determine retaining rings as required from table. Part numbers
Electronic parts catalogue
.
Installation position of synchro-rings for 1st and 2nd gear
Note
If components are not to be renewed, ensure that they are matched with their original gears.
Set inner ring
2
on synchromeshed gear
1
.
Set intermediate ring
3
in place. Lug
B
must be inserted in notch
A
.
Synchro-ring
4
is in place. Guide lugs
C
through notch
arrow
.
Checking 1st gear inner ring for wear
Check outer friction surface
arrow
for grooves or scoring and renew if necessary.
Press inner ring onto cone of synchromeshed gear and measure gap
a
using a feeler gauge.
Gap
a
New installation dimension
Wear limit
1st gear - inner ring
1.2 … 2.0 mm
0.6 mm
Checking 1st and 2nd gear intermediate ring for wear
Check inner friction surface of synchro-ring for grooves or scoring and renew if necessary.
Press inner ring, intermediate ring and synchro-ring onto cone of synchromeshed gear and measure gap
a
using a feeler gauge.
Gap
a
New installation dimension
Wear limit
1st and 2nd gear
1.4 ... 2.0 mm
0.8 mm
Pressing on synchro-hub for 1st and 2nd gears
Installation position:
High inside collar faces 2nd gear.
Assembling locking collar and synchro-hub for 1st and 2nd gears
Insert locking pieces
arrows A
in installed synchro-hub
1
.
Set locking collar
2
over synchro-hub so that the wide tooth spacing of locking collar and synchro-hub
arrow B
align.
Pressing on gear wheel for 3rd gear
Installation position:
The groove in the gear wheel faces 4th gear.
Pressing on gear wheel for 4th gear
Installation position:
High inside collar or groove on gear wheel faces 3rd gear.
Inserting spring in synchromeshed gear
The bent end of the spring
arrow
must be hooked into the hole in the synchromeshed gear.
Checking synchro-ring for wear
Press synchro-ring into locking collar and measure gap
a
with a feeler gauge at positions
A
,
B
and
C
.
Add measured values and divide by 3.
Calculated value must not be less than 0.45 mm.
Pressing on synchro-hub for 5th gear and reverse gear
Installation position:
High inner collar faces 5th gear.
Installation position of locking collar for 5th and reverse gear
Installation position:
Groove
arrow
faces reverse gear.
The locking collar is symmetrical,
It may also be installed so that the groove faces 5th gear.