Removing and installing 5th gear — VW

Removing and installing 5th gear
Special tools and workshop equipment required
Support plate
VW 309
Gearbox support
VW 353
Drift
VW 295
Drift sleeve
VW 244 B
Hot air blower
V.A.G 1416
Torque wrench
V.A.G 1331
Zweiarmabzieher Kukko 210.1
Stehbolzen M 8 x 100 mm
Support bridge
30-211A
Thrust piece
32 - 111
Thrust piece
4
from
assembly tool
T10030
Tube
VW 416 B
Puller
T10309
Two arm puller
T10040
With
puller hooks
T10040/2
Support device
T10323
Assembly tool
3253/7
Thrust piece
VW 433
Thrust plate
40 - 105
Torque wrench
V.A.G 1332
Removing
Bolt gearbox to repair stand.
Set
drip tray for workshop hoist
VAS 6208
underneath.
Drain gear oil.
Remove clutch release lever, release bearing and guide sleeve
Chapter
.
The bearings of the input shaft and output shaft must not be damaged when the 5th gear is re-installed.
Therefore, following tools must be mounted for support at this stage during attachment of gearbox to
gearbox support
VW 353
:
Underneath input shaft:
Support bridge
30-211A
Thrust piece
32 - 111
Thrust piece
4
from
assembly tool
T10030
The input shaft can be supported by the
thrust piece
32 - 111
only at a later point.
Underneath bearing support for output shaft:
Support bridge
T10323
Assembly tool
3253/7
Thrust piece
VW 433
Unbolt gearbox housing cover
arrow
.
Note
Due to changes in the gearbox housing during production, there are various procedures for removing the synchromeshed gear for fifth gear.
Proceed as follows:
Check whether
puller hooks
T10040/2A
can be inserted correctly under 5th gear wheel.
Note
When the
puller hooks
T10040/2A
can be inserted correctly, the 5th gear can be removed separately
Fig.
.
When the
puller hooks
T10040/2A
could not be inserted correctly because the puller hooks prematurely contact the wall of the gearbox housing
A
or ribs in gearbox housing beneath gear wheel
B
, remove 5th gear synchro-hub, 5th gear wheel and gearbox housing together
Chapter
.
Removing 5th gear separately
Remove selector fork for 5th gear as follows:
Cover openings with a cloth.
Move selector fork
1
to neutral position.
Remove bolt
2
with selector fork for 5th gear.
Remove both bolts
2
for pivot pins
Pull out pivot pin.
Remove selector fork.
Spring
3
and locking collar
4
do not need to be removed.
Remove bolts
A
for synchro-hub and 5th gear wheel. To do so, engage 5th gear
arrow 1
and 1st gear
arrow 2
and
arrow 3
.
Input shaft and output shaft are locked when both gears are engaged. Synchro-hub and gear wheel cannot turn. Both bolts can now be loosened.
Note
If shafts are not to be renewed, carefully clean residual locking material out of threaded holes using a thread chaser.
Pull off synchro-hub for 5th gear together with locking collar and locking pieces
Note
Use
puller
T10309
.
First set
half sleeve
T10309/1
between 5th gear wheel
A
and support for selector fork for 5th gear
B
. (If necessary, half sleeve must be pressed to end position.)
Half sleeve
T10309/1
must be positioned beneath synchro-ring.
Turn
half sleeve
T10309/1
to opposite side
direction of arrow
.
Introduce
thread insert
T10309/3
into
shell half
.
Now, fit second
half sleeve
T10309/1
, and place
tube
T10309/2
on assembly.
After pulling off synchro-hub, check for damage.
Renew synchro-ring.
Remove 5th gear synchromeshed gear with needle bearing.
Pull off gear wheel for 5th gear. (Shown here on another gearbox.)
First, install puller hook
A
.
B
Thrust plate
40 - 105
Note
When pulling off gear wheel, ensure that hooks do not bend outwards. After pulling off 5th gear wheel, examine for damage.
Heat gear wheel beforehand with
hot air blower
V.A.G 1416
if necessary.
Installing
Ensure that
support bridge
30-211A
and
support device
T10323
are installed.
Lock bolt of
support bridge
30-211A
with nut
A
.
Heat gear wheel for 5th gear to maximum 120° C.
WARNING
Wear protective gloves!
Installation position, 5th gear wheel
The circumferential groove
arrow
faces gearbox housing.
Drive on gear wheel for 5th gear.
Checking 5th gear synchro-ring
Before installing synchromeshed gear and synchro-ring for 5th gear, press synchro-ring onto cone of synchromeshed gear and measure gap
a
with a feeler gauge.
Gap
a
Installation dimension
Wear limit
5th gear
1.1 … 1.7 mm
0.5 mm
Install 5th gear synchromeshed gear with needle bearing.
Place 5th gear synchro-ring on synchromeshed gear.
If synchro-hub and locking collar for 5th gear are dismantled, assemble before installing
Fig.
.
Installation position 5th gear synchro-hub and locking collar
The pointed teeth of the locking collar
arrow 1
and the high shoulder of the synchro-hub
arrow 2
face the gearbox housing.
The supports
arrow 3
for the synchro-hub align with the cast locking pieces of the gear synchro-ring (
arrows
in figure below).
5th gear synchro-ring with cast locking pieces
arrows
Cover all openings in gearbox housing with a cloth to prevent foreign bodies from entering gearbox.
Drive on 5th gear synchro-hub.
Note
When driving on, ensure that synchro-ring moves freely.
Screw in securing bolts for synchro-hub and gear wheel for 5th gear.
The outer diameter
arrows
faces 5th gear.
Installation position of dished springs for securing bolts for gear wheel and synchro-hub for 5th gear
The outer diameter (concave side
arrows
) faces 5th gear.
Screw in bolts
A
for synchro-hub and 5th gear wheel. To do this, engage 5th gear
arrow 1
and 1st gear
arrow 2
and
arrow 3
.
Input shaft and output shaft are locked when both gears are engaged. Synchro-hub and gear wheel cannot turn. Now both bolts can be tightened to specified torque.
Install 5th gear selector fork.
Adjusting 5th gear
Engage 5th gear. Loosen bolt
1
.
Press locking collar
2
and selector jaw
3
in direction of arrow. Then, tighten bolt
1
.
Disengage 5th gear. Locking collar must now be in the neutral position. Synchro-ring must move freely.
Shift through all gears.
Apply
sealant
Electronic Parts Catalogue
evenly to sealing surface of gearbox housing cover.
Install gearbox housing cover
Chapter
.
Install left and right flange shaft with springs, thrust washers and tapered rings.
Install release bearing guide sleeve
Chapter
.
Install clutch release lever and release bearing
Chapter
.
Fill with gear oil
Chapter
.
Specified torques
Chapter
“
Specified torques – gearbox
”
Chapter
“
Assembly overview - clutch release mechanism
”
Chapter
“
Assembly overview - gearbox housing cover
”
Chapter
“
Assembly overview - gearbox housing
”