Volkswagen Tiguan Service and Repair Manual: Output Shaft, Disassembling and Assembling

Output Shaft, 1st to 4th Gears, Disassembling and Assembling

Special tools and workshop equipment required

• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW407-
• Press Piece - Rod -VW408A-
• Press Piece - Multiple Use -VW412-
• Press Piece - 60mm -VW415A-
• Holding Plate -VW309A-
• or Holding Plate - VW309A-
• Holding Fixture -VW313-
• Transmission Support -VW353-
• Press Piece - Multiple Use -VW431-
• Press Piece - Multiple Use -VW433-
• Press Piece - Multiple Use -VW454-
• Press Piece - Multiple Use -VW512-
• Press Piece - 42mm -VW516-
• Press Piece - Multiple Use -VW519-
• Slide Hammer Set -VW771-
• Crankshaft Holding Fixture -VW801-
• Press Piece - Multiple Use -40-105-
• Bearing Installer - Multiple Use -40-20-
• Bearing Installer - Differential Bearing -40-21-
• Slide Hammer - Press Plate -2050-
• Holding Fixture - Spacers -VW540/1B-
• Puller - Taper Roller Bearing -VAG1582-
• Puller - Taper Roller Bearing - Adapter 7 -VAG1582/7-
• Inductive Heater -VAS6414-
• -1-Puller - Kukko Internal - 46-56mm -21/7-
• -1-Puller - Kukko Internal - 56-70mm -Kukko 21/8-
• -2-Puller - Kukko Puller - 60-200mm Width, 250mm Length -18/2-
• -3-Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-
• -4-Puller - Kukko Counterstay -22/2-

Removing the Dished Washer -A- from the Output Shaft

Installing the Dished Washer into the Output Shaft

Dimension "a" = 2 mm

Removing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing

1. Puller - Quick Action Separating Tool - 22-115mm, for example -Kukko 17/2-

Installing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing

Removing the Outer Race / Tapered Roller Bearing from the Clutch Housing

1. Puller - Kukko Counterstay -22/2-, for example.
2. Puller - Kukko Internal - 56-70mm -21/8-, for example.

Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing

• Support the clutch housing with the Bearing Installer - Multiple Use -40-20- directly under the bearing mount.

Remove the Bearing Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing

Note the following before installing the Tapered Roller Bearing Puller:

• Remove the bearing inner race/tapered roller bearing locking ring on the side facing the transmission housing.
• Place the Press Piece - Multiple Use -VW431- in the output shaft and lay the Press Piece - Multiple Use - 40-105- on top.

Installing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing

• Choose the correct locking ring.

Selecting the Locking Ring

• Choose and install the thickest locking ring that will fit.

Note

Allocate the correct locking rings. Refer to the Parts Catalog.

The following locking rings are available:

Thickness (mm)
1.79	1.83	1.86	1.89
1.92	1.95	1.98

Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.

• Install the adjusting shim under the outer race.
• Support the transmission housing under the bearing mount using the Slide Hammer - Press Plate -2050-.

Disassembling the Output Shaft

Note

Remove the bearing inner race/tapered roller bearing on the side of the transmission housing.

Removing the 3rd and 4th Gear Synchronizer Hub/Locking Collar with the 4th Gear Wheel

• Remove the locking ring beforehand.

1. Puller, for example, Puller - Kukko Puller - 60-200mm Width, 250mm Length -18/2-
2. Puller - Quick Action Separating Tool - 22-115mm -17/2-, for example.

• Then remove the retaining ring -item 20- and thrust washers -item 19-
• Then remove the 1st gear wheel with synchronizer ring.

On Transmissions with Reinforcement Measures, Remove the Collar Bushing -B- Together with the 1st Gear Wheel -C-.

Allocate Transmission Via Code Letters. Manual Transmission 0FB, for CC, Passat, Golf.

1. Puller - Quick Action Separating Tool - 22-115mm -17/2-, for example.

• Install the Separating Tool-A- underneath the helical-cut gear teeth on the 1st gear wheel.

Removing the Locking Collar and the Synchronizer Hub for 1st and 2nd Gear

After removing the circlip, press off the gear wheel for 2nd gear and locking collar/synchronizer hub together.

Assemble the Output Shaft.

Note

Heat the tapered roller bearing inner races and synchronizer hub to approximately 100 ºC (212 ºF) with the Inductive Heat Unit -VAS6414- before installing. Press on to the stop so that there is no axial clearance.

Inner Friction Surface on 1st Gear Outer Race, 2nd Gear Outer Race and 3rd Gear Outer Race, Checking for Wear

• Install the inner race -1- on the cone on the gear wheel.
• Install the outer race -2- on the cone on the inner race. Measure the gap -a- with a feeler gauge at 3 locations at 120º.
• Note the average value.

Wear Limit Dimension -a-
1st gear, 2nd gear, and 3rd gear	0.4 mm

Outer Friction Surface on 1st Gear Outer Race, 2nd Gear Outer Race and 3rd Gear Outer Race, Checking for Wear

• Check the synchronizer ring -arrow- on the inner running surface for grooves and radial wear, and replace if necessary.
• Install the inner race, the outer race and the synchronizer ring on the cone on the inner race.
• Press the synchronizer ring onto the outer races while turning it at the same time so that it seats correctly.
• Measure the gap -a- with a feeler gauge at 3 locations at 120º.
• Note the average value.

Wear Limit Dimension -a-
1st gear, 2nd gear, and 3rd gear	0.8 mm

• Install the 2nd gear wheel with the needle bearing.

Installing 2nd Gear Outer Race, Inner Race and Synchronizer Ring

• Place inner race -A- on 2nd gear wheel.

The tabs -1- face away from the gear wheel.

• Install the outer race -B-.

The tabs -2- engage in grooves -3- on the gear wheel.

• Install the synchronizer ring -C-.

The larger openings -4- lock in the tabs -1- on the inner race -A-.

Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears

1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer Hub

• Slide the locking collar over the synchronizer hub.

In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Assembling the Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears

The locking collar is pushed over the synchronizer hub.

• Install the locking pieces and springs offset by 120º. The angled end of the spring must engage into the hollow locking piece.

Installation Position of Locking Collar/Synchronizer Hub for 1st and 2nd Gears

The identification groove -arrow 1- and the narrow collar -arrow 2- on the synchronizer hub face the 1st gear.

Warming and Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears

The pins -A- on the synchronizer ring lock into the recesses -B- in the synchronizer hub.

• Install the locking ring.

Installing the Synchronizer Ring for 1st Gear Outer Race and Inner Race

• Install the synchronizer ring -A- into the 1st and 2nd gear synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

• Install the outer race -B- in the synchronizer ring.

The tabs -3- face away from the synchronizer ring.

• Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Installing 1st Gear Wheel with Needle Bearing

• The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear wheel -3-.

• Install the 1st and 4th gear thrust washers in the output shaft -item 19- and -item 20-

On Transmissions with Reinforcement Measures, Install Collar Bushing -A- to Stop.

Allocate Transmission Using the Code Letters (for Manual Transmission 0FB in CC, Passat and Golf.

• Installation position of the collar bushing -A-: The collar -arrow- points to the 1st gear wheel.
• Then install the 4th gear wheel with needle bearing.

Checking the 4th Gear Synchronizer Ring for Wear

-A- = Brass Synchronizer Ring
Gap dimension -a-	Installation Dimension	Wear limit
4th Gear	1.0 to 1.7 mm	0.5 mm

 

-B- = Steel Synchronizer Ring
Gap Dimension -a-	Installation Dimension	Wear Limit
4th Gear	1.3 to 2.4 mm	0.8 mm

• Press synchronizer ring onto taper of the gear wheel and measure gap dimension -a- using a feeler gauge.

Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears

The wider collar on the synchronizer hub -arrow- faces the 3rd gear.

• Place the synchronizer ring for 4th gear on the 4th gear wheel.

Warming and Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears

• Turn the 4th gear synchronizer ring so that the grooves line up with the locking pieces.
• Install the locking ring.

Installing the 3rd Gear Synchronizer Ring, Outer Ring and Inner Ring

• Install the synchronizer ring -A- into the 3rd and 4th gear synchronizer hub.

The tabs -1- lock in the openings -2- in the synchronizer hub.

• Install the outer race -B- in the synchronizer

The tabs -3- face away from the synchronizer ring.

• Install the inner race -C- in the outer race.

The tabs -4- lock in the larger openings -5- in the synchronizer ring -A-.

Installing the 3rd Gear Wheel with Needle Bearing

• The synchronizer ring -1- and the tabs -arrow A- are inside the openings in the synchronizer hub -2-.

The pins -arrows B- in the outer race lock in the recesses -arrows C- in the gear wheel -3-.

Note

• Installing the bearing inner race/taper roller bearing.
• Selecting the locking ring for the bearing inner race/tapered roller bearing.

Output Shaft, 5th, 6th and Reverse Gears, Disassembling and Assembling

Special tools and workshop equipment required

• Press Plate -VW401-
• Press Plate -VW402-
• Press Piece - Rod -VW407-
• Press Piece - Rod -VW408A-
• Press Piece - Multiple Use -VW412-
• Press Piece - 60mm -VW415A-
• Holding Fixture -VW313-
• Holding Plate -VW309A-
• or Holding Plate - VW309A-
• Transmission Support -VW353-
• Press Piece - Multiple Use -VW433-
• Press Piece - Multiple Use -VW454-
• Support Channels -VW457-
• Crankshaft Holding Fixture -VW801-
• Press Piece - Multiple Use -VW431-
• Press Piece - Multiple Use -VW455-
• Press Piece - Multiple Use -VW510-
• Press Piece - 42mm -VW516-
• Press Piece - Multiple Use -VW519-
• Press Piece - Multiple Use -30-11-
• Press Piece - Multiple Use -40-105-
• Bearing Installer - Multiple Use -40-20-
• Slide Hammer - Press Plate -2050-
• Press Piece - Reverse Gear Syncro -3296-
• Puller - Taper Roller Bearing -VAG1582-
• Puller - Taper Roller Bearing - Adapter 4 -VAG1582/4-
• Puller - Taper Roller Bearing - Adapter 7 -VAG1582/7-
• Inductive Heater -VAS6414-
• -1-Puller - Kukko Internal - 46-56mm -21/7-
• -3-Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-
• -4-Puller - Kukko Counterstay -22/2-

Removing the Outer Race/Tapered Roller Bearing from the Clutch Housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

Note

Check the washer for damage after removing it and replace if necessary.

Installing the Outer Race/Tapered Roller Bearing in the Clutch Housing

• Place the washer under the outer race.
• Support the clutch housing with the Bearing Installer - Multiple Use -40-20- directly under the bearing mount.

Removing the Outer Race/Tapered Roller Bearing from the Transmission Housing

1. Counter Support, for example, Puller - Kukko Counterstay -22/2-
2. Internal Puller 46 to 58 mm, for example, Puller - Kukko Internal - 46-56mm -21/7-

Installing the Outer Race/Tapered Roller Bearing into the Transmission Housing.

• Support the transmission housing under the bearing mount using the Slide Hammer - Press Plate -2050-.

Disassembling the Output Shaft

Remove the Bearing Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing

Note the following before installing the Tapered Roller Bearing Puller:

• Remove the bearing inner race/tapered roller bearing locking ring on the side facing the transmission housing.
• Place the Press Piece - Multiple Use -VW431- and Press Piece - Multiple Use -40-105- on the output shaft.

Removing the 5th and 6th Gear Synchronizer Hub/Locking Collar with the 6th Gear Wheel

• Remove the locking ring beforehand.

Removing the Sleeve -A- Together with the Reverse Gear Wheel

• Remove the locking ring beforehand.

Removing the Reverse Gear Synchronizer Hub

• Remove the locking ring beforehand.

1. 22 to 115 mm Separating Tool, for example Puller - Kukko Quick Action Separating Tool - 22-115mm -17/2-

Removing the Bearing Inner Race/Tapered Roller Bearing on the Side of the Clutch Housing.

• Mount the Press Piece - Multiple Use -30-11- on the output shaft before removing the puller.

Assemble the Output Shaft.

Note

Heat the tapered roller bearing inner races and synchronizer hub to approximately 100 ºC (212 ºF) with the Inductive Heat Unit -VAS6414- before installing. Press on to the stop so that there is no axial clearance.

Installed Position: Reverse Gear Synchronizer Hub

The stop -arrow A- on the reverse gear locking collar faces the splines on the output shaft -arrow B-.

Warming and Installing the Reverse Gear Synchronizer Hub

• Install the locking ring.
• Mount the reverse gear locking collar on the reverse gear synchronizer hub.
• Install the reverse gear wheel and the needle bearing.

Installing the Sleeve -A-

Installed position: wide collar points toward reverse gear selector gear.

• Install the locking ring.

Check the 5th and 6th Gear Synchronizer Ring For Wear

-A- = Brass Synchronizer Ring
Gap Dimension -a-	Installation Dimension	Wear Limit
5th and 6th gear	1.0 to 1.7 mm	0.5 mm

 

-B- = Steel Synchronizer Ring
Gap Dimension -a-	Installation Dimension	Wear Limit
5th and 6th gear	1.2 to 2.1 mm	0.8 mm

• Press synchronizer ring onto taper of the gear wheel and measure gap dimension -a- using a feeler gauge.

Disassembling and Assembling Locking Collar and Synchronizer Hub for 5th and 6th Gears

1. Spring
2. Locking piece
3. Locking collar
4. Synchronizer Hub

• Slide the locking collar over the synchronizer hub.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.