Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling - 6 Spd. Manual Transmission 01E
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Press tool VW 412
^ Tube VW 519
^ Feeler gauge
Note:
When installing new gears
1 - Gearbox 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
^ After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
6 - Synchro-ring for 4th gear
^ Check for wear
7 - Locking collar
^ Paired with synchro-hub
^ Mark before removing
8 - Circlip
^ Re-determine thickness when replacing synchro-hub
^ Installation position: ends align with groove of synchro-hub
9 - Synchro-hub for 3rd and 4th gear
10 - Synchro-ring for 3rd gear
^ Coated with molybdenum
^ Check for wear
11 - 3rd speed sliding gear
^ Before installing, insert spring
^ 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
15 - Bearing plate
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
^ After installing, check axial clearance with a feeler gauge (0.15-0.35 mm)
21 - Synchro-ring for 6th gear
^ Check for wear
22 - Synchro-hub for 5th and 6th gear
^ Installation position: projecting hub towards 5th speed sliding gear
23 - Locking collar
^ Paired with synchro-hub
^ Mark before removing
24 - Synchro-ring for 5th gear
^ Check for wear
25 - 5th speed sliding gear
^ Before installing, insert spring
^ After installing, check axial clearance
26 - Inner race for 5th speed sliding gear
27 - Needle bearing for 5th gear
^ Oil with gear oil before installing
28 - 1st inner race for tapered roller bearing for input shaft
29 - End cover
30 - 2nd inner race for tapered roller bearing for input shaft
31 - Multi-point socket head bolt, 150 Nm
^ Loosening and tightening
Insert spring in sliding gear
- Insert spring (arrow) in sliding gear, hook angled end into hole.
Check 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
Re-determining thickness of circlip
- Press synchro-hub onto stop.
Note:
Note installation position when pressing on.
- 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.
Circlips available
- Fit circlip.
Press off synchro-hub for 3rd and 4th gear
Synchro-hub installation position
^ Oil groove in synchro hub (arrow -1-) must align with oil drilling -arrow 2- in input shaft
Press on synchro-hub for 3rd and 4th gear
- Heat synchro-hub to approx. 100° C, fit and press home.
- Fit circlip.
Drive 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.