Dismantling and assembling reverse shaft: VW 1.8 (BBU)

Note:

After dismantling, always renew needle roller bearing in clutch housing and reverse shaft support.

Clutch housing
Needle roller bearing
Pulling out => Fig.
1
Pressing in => Fig.
2
Modification:
Modified to suit modified reverse gear wheel from gearbox build date 18 09 0=> Fig.
3
Pressing in => Fig.
4

Reverse gear wheel
Modification:
Modified in area of needle roller bearing from gearbox build date 18 09 0 => Fig.
3

Note:

When changing the previous reverse gear wheel for the new type always install the new needle roller bearing.

Circlip
Always renew after removing

Reverse sliding gear wheel
Before replacing remove circlip
Shoulder faces to reverse gear wheel

Reverse shaft
Removing => from Page
34-73
Modification:
From gearbox build date 15 08 0, modified in area of needle roller bearing (item
8
) => Fig.
5

Thrust washer
Modification:
Deleted from gearbox build date
15 08 0 => Fig.
5

Needle roller bearing
Pressing out => Fig.
6
Pressing in => Fig.7

Reverse shaft support
Removing and installing
=> from Page
34-73

Fig.1
Pulling needle roller bearing out of clutch housing

A - Counter support, e.g. Kukko 22/1

B - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2

Note:

The needle bearing is destroyed during removal and must be renewed.

Fig.2
Pressing needle roller bearing into clutch housing

Up to gearbox build date 17 09 0

Fig.3
Modified needle roller bearing and reverse gear wheel

From gearbox build date 18 09 0.
The groove (arrow) on the clutch housing side of the reverse gear wheel has been deleted.
At the same time the depth of the needle roller bearing sleeve collar has been reduced to prevent it making contact with the gear wheel.

Gearbox build date · Dimension a mm
from 18 09 0 · 3.85
up to 17 09 0 · 5.00

Note:

The modified gear wheel can be installed in earlier gearboxes. When exchanging an earlier reverse gear wheel for a new type wheel always install with a new type needle roller bearing.

Fig.4
Pressing needle roller bearing -A- into clutch housing

From gearbox build date 18 09 0

Fig.5
Modified reverse gear shaft

The reverse gear shaft, needle roller bearing spigot has been reduced (dimension -a-)

Gearbox build date · Dimension a mm
from 15 08 0 · 20.0
up to 14 08 0 · 21.0

The washer -A- is then deleted

Note:

The modified reverse shaft can also be installed in previous gearboxes. In this case the washer -A- must not be installed.

Fig.6
Pressing needle roller bearing out of the reverse shaft support

Fig.7
Pressing needle roller bearing into reverse shaft support