- Place a spacer puller under the 2nd gear, which rotates freely on the shaft, and remove it.
- Remove the retaining ring.
- Remove the 1st and 2nd gear synchronizer clutch and hub.
- The selection of new gears or a new secondary shaft should be carried out taking into account the technical characteristics of the gearbox being repaired.
- Tapered roller bearings are replaced in pairs.
List of parts of the assembly unit "Secondary shaft" of gearbox type 0A4 with technological notes to figure VC4.101:
1. Hex nut: 25 Nm and tighten by turning 90°:
- 4 pcs., for fastening the bearing cup of the intermediate support.
2. Clutch housing.
3. Secondary shaft adjusting washer.
4. Outer ring of small tapered roller bearing.
5. Inner ring with cage of small tapered roller bearing.
6. Secondary shaft.
7. Inner ring with a large tapered roller bearing cage.
8. Sealing ring:
- 4 pcs., installed on the bearing cup mounting bolts of the intermediate support.
9. Bearing cup with outer ring of large tapered roller bearing and bolts:
- the outer ring is replaced only in a set with a large tapered roller bearing and bearing cup.
10. Thrust washer:
- is installed with a step towards the tapered roller bearing.
11. 1st gear freely rotating on the shaft.
12. Needle bearing of 1st gear.
13. Inner ring of 1st gear synchronizer:
- check for wear;
- check the protrusions for signs of intense wear.
14. Intermediate ring of 1st gear synchronizer:
- check for wear;
- replace if there are grooves and signs of intense wear.
15. 1st gear synchronizer locking ring:
- check for wear.
16. Clutch and hub of synchronizer 1st and 2nd gears:
- after removing the retaining ring;
- removed together with the intermediate support bearing cup.
17. Retaining ring.
18. 2nd gear synchronizer locking ring:
- check for wear;
- install so that the synchronizer clutch crackers fit into the grooves of the ring.
19. Intermediate ring of 2nd gear synchronizer:
- installed in the locking (outer) ring of the synchronizer;
- replace if there are grooves and signs of intense wear.
20. Inner ring of 2nd gear synchronizer:
- check for wear;
- check the protrusions for signs of intense wear.
21. 2nd gear freely rotating on the shaft.
22. Needle bearing of 2nd gear.
23. Thrust washer.
24. Sleeve for needle bearing of 3rd gear gear;
- is removed together with the 2nd gear gear, which rotates freely on the shaft.
25. Needle bearing of 3rd gear.
26. 3rd gear freely rotating on the shaft.
27. 3rd gear synchronizer locking ring:
- check for wear.
28. Clutch and hub of synchronizer 3rd and 4th gears:
- removed together with the 2nd and 3rd gear gears rotating freely on the shaft.
29. Needle bearing bushing:
- removed together with the clutch and hub of the synchronizer of 3rd and 4th gears.
30. Needle bearing of 4th gear.
31. 4th gear synchronizer locking ring:
- check for wear.
32. 4th gear freely rotating on the shaft.
33. Thrust washer.
34. Secondary shaft needle bearing.
35. Gearbox housing.
36. Sleeve for secondary shaft needle bearing.
37. 5th gear pinion.
38. Disc spring.
39. Screw M10: 80 Nm:
- must be replaced.
Pressing out the outer ring of a small tapered roller bearing:
Pressing in the outer ring of a small tapered roller bearing:
Removing the inner race of a small tapered roller bearing:
Place the clamp behind the bearing race and tighten the clamp as much as possible. After this, turn the bearing and tighten the clamp again.
The original text can be found on the portal [VWmanual.ru]
Pressing on the inner ring with the cage of a small tapered roller bearing:
Removing the hub and synchronizer clutch of 3rd and 4th gears, freely rotating on the shaft of the gears of 2nd, 3rd and 4th gears and the sleeve under the needle bearing of the secondary shaft:
Install the separating puller in such a way that when removing the necessary parts, the 1st and 2nd gear synchronizer sleeve is not also removed.
Removing the clutch and synchronizer hub together with the intermediate support bearing cup:
First, you need to remove the retaining ring (arrow).
Removing the inner race of a large tapered roller bearing:
Before installing the puller, screw a hex head screw M10x20 into the hole on the end of the secondary shaft.
Pressing on the inner ring with the cage of a large tapered roller bearing:
Before pressing, install a thrust washer onto the shaft with the shoulder towards the inner ring.
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