Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling
Special tools, testers and auxiliary items required:
^ Thrust plate VW 401
^ Press tool VW 412
^ Tube VW519
^ Feeler gauge
Note: When installing new gears, Refer to Manual Transaxle, Application and ID
1. Gearbox housing
^ Servicing, Refer to Transmission Disassembling and Assembling, Transmission Housing, Servicing
2. Circlip
3. Thrust washer
4. Needle bearing for 4th gear
^ Mark before removing
^ Do not interchange with needle bearing for 3rd gear
^ Oil with gear oil before installing
5. 4th speed sliding gear
^ Before installing, insert spring, Refer to Fig. 1
^ After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
6. Synchroring for 4th gear
^ Check for wear, Refer to Fig. 2
7. Locking collar
^ Paired with synchrohub
^ Mark before removing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
8. Circlip
^ Redetermine thickness when replacing synchrohub, Refer to Fig. 3
^ Installation position: ends align with groove of synchrohub
9. Synchrohub for 3rd and 4th gear
^ Pressing off, Refer to Fig. 4
^ Installation position, Refer to Fig. 5
^ Pressing on, Refer to Fig. 6
10. Synchroring for 3rd gear
^ Coated with molybdenum
^ Check for wear, Refer to Fig. 2
11. 3rd speed sliding gear
^ Before installing, insert spring, Refer to Fig. 1
^ After pressing on -item 9-, check axial clearance with a feeler gauge (0.15-0.35 mm)
12. Needle bearing for 3rd gear
^ Mark before removing
^ Do not interchange with needle bearing for 4th gear
^ Oil with gear oil before installing
13. Input shaft
14. Spring pin
^ Drive in when replacing input shaft, Refer to Fig. 7
15. Bearing plate
^ Servicing, Refer to Bearing Plate, Servicing
16. Inner race for cylinder roller bearing
^ Take off and fit by hand
17. Circlip
18. Thrust washer for needle bearing for 6th gear
^ Installation position: shoulder towards circlip, smooth contact surface towards needle bearing
19. Needle bearing for 6th gear
^ Oil with gear oil before installing
20. 6th speed sliding gear
^ Before installing, insert spring, Refer to Fig. 1
^ After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
21. Synchroring for 6th gear
^ Check for wear, Refer to Fig. 2
22. Synchrohub for 5th and 6th gear
^ Pulling off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Driving on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Installation position: projecting hub towards 5th speed sliding gear
23. Locking collar
^ Paired with synchrohub
^ Mark before removing, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
24. Synchroring for 5th gear
^ Checking for wear, Refer to Fig.2
25. 5th speed sliding gear
^ Before installing, insert spring, Refer to Fig. 1
^ After installing, check axial clearance, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
26. Inner race for 5th speed sliding gear
^ Pulling off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Driving on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
27. Needle bearing for 5th gear
^ Oil with gear oil before installing
28. 1st inner race for tapered roller bearing for input shaft
^ Pulling off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Driving on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
29. End cover
^ Servicing, Refer to End Cover, Servicing
30. 2nd inner race for tapered roller bearing for input shaft
^ Pulling off, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
^ Driving on, Refer to Bearing Housing, Torsen Differential, End Cover, Internal Selector Mechanism, Input Shaft, Drive Pinion and Hollow Shaft, Removing and installing (assembly Sequence)
31. Multipoint socket head bolt, 150 Nm
Fig. 1 Inserting spring in sliding gear
- Insert spring (arrow) in sliding gear, hook angled end into hole.
Fig. 2 Checking synchro-ring for wear
- Press synchro-ring into locking collar and measure gap "a" with a feeler gauge at positions -A-, -B- and -C-.
- Add together results and divide by three.
^ The figure calculated must not be less than 0.5 mm
Fig. 3 Re-determining thickness of circlip
- Press synchro-hub onto stop.
Note: Note installation position when pressing on, Refer to Fig. 5.
- Determine thickest circlip that can still just be fitted.
Note: The opening of the circlip must align with the groove in the synchro-hub.
- Determine circlip from table.
Refer to Parts Supplier
Circlips available
- Fit circlip.
Fig. 4 Pressing off synchro-hub for 3rd and 4th gear
Fig. 5 Synchro-hub installation position
- Oil groove in synchro hub (arrow-1) must align with oil drilling -arrow 2- in input shaft
Fig. 6 Pressing on synchro-hub for 3rd and 4th gear
- Heat synchro-hub to approximately 100°C, fit and press home.
- Fit circlip.
Fig. 7 Driving spring pin into input shaft
- Guide a 9 mm diameter drift -A- into oil drilling and drive spring pin -B- in until it touches drift.