17. Remove the 1st speed gear 12-needle bearing 11.
18. Remove the 1st speed synchronizer ring 10.
19 Remove the thrust washer (if any), and then use pliers to remove the spring ring 9 from the 1st and 2nd speed synchronizer unit. During installation, it is necessary to install a new safety spring ring.
20. Having secured the puller below the 2nd speed gear, it is necessary to pull out the gear together with the 1st and 2nd speed synchronizer unit. After extraction, disassemble the unit into parts and take out the 2nd speed synchronizer ring 7.
21. Remove the needle bearing of the 2nd speed gear 5.
22. Clean the elements in kerosene and check them for wear. Check the teeth of the toothed gear (release) and needles. If necessary, replace the elements with new ones. If the toothed gears of the 3rd, 4th, and 4th speeds 3 require replacement, this must be done on a press. New toothed gears must be heated to a temperature of 128°C before installation. It is necessary to pay attention that the seats of both toothed gears are close to each other. The toothed gear on the output shaft and the large toothed gear of the main transmission are not adjusted to each other, so if necessary, the output shaft can be replaced without the need to replace the large gear. In this case, it is necessary to check and, if necessary, adjust the longitudinal clearance of the output shaft.
When installing a new output shaft, it is necessary to check the number of teeth on the small gear of the transmission, comparing with the old shaft. The output shaft on the landing surface of the 4th and 3rd speed gears has channels that serve for identification.
For transmission
4.27 — (64:15) shaft without channel
3.88 - (62:16) single channel shaft
4.05 - (65:16) shaft with three channels.
23. Check the synchronizer rings and synchronizer units.
Installation
24. Installation should begin with placing the 2nd speed gear needle bearing on the input shaft. Lubricate it with gearbox oil.
25. Install the 2nd speed gear 6.
26. Install the 2nd speed synchronizer ring into the 1st and 2nd speed synchronizer unit so that the 2nd synchronizer crackers are in the cutouts of the ring.
27. Press the synchronizer unit onto the shaft splines after installing the synchronizer unit; the groove of the forks of the movable gear 8 should be on the side of the 1st speed gear.
28. Install a new spring ring 9 into the shaft groove, and then the thrust washer (if any).
29. Install the 1st speed synchronizer ring into the 1st and 2nd speed synchronizer unit so that the synchronizer crackers are in the cutouts of the ring.
30. Install the needle bearing 11 of the 1st speed gear on the shaft and lubricate it with gearbox oil, then install the 1st speed gear 12.
31. Install the support washer 13 and the new spring ring 14, checking that it fits precisely into the groove.
Figure 6.5. Input shaft of gearbox 084
1 - spring ring; 2 - spacer washer; 3 - ball bearing; 4 - input shaft; 5 - needle bearing; 6 - 3rd speed gear; 7 - 3rd speed synchronizer ring; 8 - spring ring; 9 - spacer washer; 10 - 4th speed synchronizer ring; 11 - needle bearing; 12 - 4th speed gear; 13 - spring ring; 14 - needle bearing; 15 - ring that holds the crackers; 16 - synchronizer hub; 17 - synchronizer housing; 18- synchronizer blocks; 19 - ring that holds the crackers.
(The information is available on the website: VWmanual)
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