Repairing bearing plate — VW

VW
Passat
1997
Power transmission
6-speed manual gearbox 01E, four-wheel drive
Edition
04.2005
Repairing bearing plate
Special tools and workshop equipment required
Press tool
VW 408 A
Guide pin
10-15
Press tool
30-504
Torque wrench
V.A.G 1331
1
-
Internal puller
Kukko 21/2
4
-
Counterhold
Kukko 22/1
Bearing plate
If renewed, redetermine shim S
4
.
Small tapered roller bearing outer race of pinion shaft
Driving out
Fig.
.
Pressing in
Fig.
.
If renewed, redetermine shim S
4
.
Shim S
4
Adjustment overview
Chapter
.
Redetermining
Chapter
.
Cylindrical roller bearing for input shaft
Pressing out
Fig.
.
Pressing in
Fig.
.
Measuring pressing depth
Fig.
.
Ball sleeves
Qty. 4.
Always renew.
For selector rods:
Driving in and out
Fig.
.
For reverse gear yoke:
Pulling out
Fig.
.
Driving in
Fig.
.
Bolt, 35 Nm
For relay lever.
Dowel pin (7 x 28)
Drive out and in with a drift.
Reverse gear
For reverse gear.
Reverse gear synchro-ring
With locking pins.
Check for wear
Fig.
.
Installation position: flat on circumference of synchro-ring faces towards input shaft
Anchor
.
Compression spring
Installation position: hook end with one bend into notch in synchro-ring. Turn end with two bends anti-clockwise and insert into perforation in bearing plate.
Reverse gear axle
Support plate
Installation position: chamfers of holes for locking pins of synchro-ring towards bearing plate
Anchor
Spring clip
Bolt, 25 Nm
Self-locking.
Always renew.
Relay lever for reverse gear
Yoke for reverse gear
Pulling out ball sleeve
Fig.
.
Driving in ball sleeve
Fig.
.
Selector rod for 5th and 6th gear
Renew only complete with yoke
Item
.
Removing and installing ball sleeves for selector rods.
Install ball sleeve with inscribed side (thicker metal) facing drift.
Pressing dimension
a
= 2.5 mm
Checking synchro-ring for wear
Press synchro-ring onto cone of reverse gear and measure gap
a
using feeler gauge.
Dimension, new: 0.75...2.3 mm
Wear limit: 0.2 mm
Pulling ball sleeve out of reverse gear yoke
A
Counter support, e.g.
Kukko 22/1
B
Internal puller, 14.5...18.5 mm, e.g.
Kukko 21/2
Driving ball sleeve flush into reverse gear yoke
Install ball sleeve with inscribed side (thicker metal) facing drift.
Pressing cylindrical roller bearing for input shaft out of bearing plate
Pressing cylindrical roller bearing for input shaft into bearing plate
Measuring pressing depth
Fig.
.
Measuring insertion depth of cylinder roller bearing for input shaft
Pressing depth
a
= 7 mm