Input Shaft Replacement: Overview

Notes:
- When installing new gears or a new input shaft refer to "Application and Identification" and "Service Precautions"
- Because the circlips used differ in size and thickness, individual circlips must be marked (mark with the numbers: refer to "Location of Circlips" at "Procedures"). The required thickness of a particular circlip must be re-determined whenever a directly affected component is replaced.






1. Circlip
- Determining thickness: refer to "Input Shaft, Adjusting"
- If ball bearing and input shaft are reused, measure thickness of circlip with micrometer and install circlip of same thickness
2. Ball bearing for input shaft
- Remove before removing input shaft: refer to "Sequence Of Operations" at Transmission Housing.
- Install after installing input shaft: refer to "Sequence Of Operations" at Transmission Housing.
3. Circlip
- Determining thickness: refer to "Input Shaft, Adjusting"
- If ball bearing and input shaft are reused, measure thickness of circlip with micrometer and install circlip of same thickness
4. Transmission housing
5. Needle bearing for input shaft
- Removing: refer to "Procedures" at Controls and Housing/Housing, Disassembling and Assembling/Input Shaft Bearing, Multi-Function Switch
- Install with thrust pad 40-202
- Insertion depth of needle bearing: refer to "Procedures" at Controls and Housing/Housing, Disassembling and Assembling/Input Shaft Bearing, Multi-Function Switch
6. Input shaft
- Refer to Adjusting
- Inserting into ball bearing: refer to "Sequence Of Operations" at Transmission Housing.
7. Needle bearing for 3rd gear
8. 3rd gear
- Insert spring before installing: refer to "Procedures"
9. Synchronizer ring for 3rd gear
- Check for wear: refer to "Procedures"
10. Circlip
- Location: refer to "Procedures"
11. Synchronizer hub for 3rd and 4th gear
- High inner shoulder faces 3rd gear
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
12. Circlip
- Re-determine thickness when replacing synchronizer hub
- Location and table: refer to "Procedures"
- Determining: refer to "Procedures"
13. Operating sleeve for 3rd and 4th gear
- Installation position: refer to "Procedures"
14. Synchronizer ring for 4th gear
- Check for wear: refer to "Procedures"
15. 4th gear
- Insert spring before installing: refer to "Procedures"
16. Needle bearing for 4th gear
17. 5th gear
- Removing: refer to "Procedures"
- Installing: refer to "Procedures"
18. Circlip
- Re-determine thickness when replacing 5th gear
- Location and table: refer to "Procedures"
- Determining: refer to "Procedures"
19. Needle bearing for input shaft
- Is damaged when removing
- Always replace
- Removing: refer to "Procedures" at Controls and Housing/Disassembling and Assembling/Shift Mechanism, Input Shaft, Pinion, Cover
- Knock with drift VW 295, the adapter tool VW 295a and the tube section VW 416b
- Installation position: refer to "Procedures" at Controls and Housing/Disassembling and Assembling/Shift Mechanism, Input Shaft, Pinion, Cover
20. Plastic sleeve
- Always replace
21. Transmission cover