Disassembly and assembly of the primary shaft of the gearbox (VW Passat B2)

Disassembly

Remove the retaining ring with pliers.

Remove the thrust washer of the fourth gear pinion, the needle bearing and the fourth gear pinion from the shaft.

Remove the 4th gear synchronizer locking ring, then the synchronizer retaining ring.

Press the sliding clutch with the synchronizer locking ring and the third gear pinion on a press. Remove the third gear pinion needle bearing.

Assembly

Install the needle bearing and 3rd gear gear on the shaft.

Check the wear of the synchronizer locking rings by pressing the synchronizer locking rings against the gear synchronizer cones and using a feeler gauge measure the axial clearance between the end of the locking ring and the end of the gear synchronizer toothed ring, which should be at least 0.5 mm. If the clearance is smaller, replace the synchronizer locking rings.

Install the 3rd gear synchronizer locking ring.

Connect the sliding coupling to the synchronizer hub of the third and fourth gears, directing the internal splines of the hub with the beveled edge towards the third gear pinion. The annular groove of the hub should be facing the fourth gear pinion. After installing three synchronizer crackers, install the springs, placing their connectors every 120°, while the curved ends of the springs must be inserted into the cracker recesses.

Press the synchronizer onto the primary shaft, turning the locking ring of the 3rd gear synchronizer so that the projections of the ring enter the grooves of the sliding clutch hub, and the beveled edge of the internal splines of the hub is directed towards the 3rd gear gear.



Install the 4th gear synchronizer locking ring and install the retaining ring.

Press the 4th gear pinion with a needle bearing onto the shaft.

Move the third gear pinion and synchronizer until they stop against the retaining ring.

Measure the axial clearance of the fourth gear pinion with a set of feeler gauges; it should be in the range of 0.10-0.40 mm. Select the appropriate thrust washer to obtain the smallest clearance.

Install the retaining ring.