Input Shaft, Disassembling and Assembling

Input shaft, disassembling and assembling





Special tools and workshop equipment required
^ VW 407 Press tool
^ VW 447 H Press plate
^ VW 412 Press tool
^ VW 422 Tube
^ VW 401 Press plate
^ VW 408 A Press tool





Special tools and workshop equipment required
^ VW 454 Press piece 41 501 Drift sleeve
^ VW 447 Thrust plate
^ VW 510 Press piece

Notes:
^ When installing new gears, consult technical data
^ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be readjusted. See adjustment overview, Refer to Differential Assembly, Adjustments





1. Clutch housing
2. Taper roller bearing outer race
^ Removing, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
3. Taper roller bearing inner race
^ Knock - off the input shaft with a drift
^ Pressing on
4. Input shaft
^ Adjusting, Refer to Overhaul Subassemblies, Input Shaft, Adjusting
5. 3rd gear
^ Shoulder points to 4th gear
6 Pressing off, Refer to Fig. 5
^ Pressing on, Refer to Fig. 6
6. Circlip
^ Always replace
7. 4th gear
^ Pressing off with taper roller bearing outer race and sleeve , Refer to Fig. 4
^ Pressing on, Refer to Fig. 7
^ Collar faces to 3rd gear
8. Taper roller bearing inner race Pressing off with 4th gear and, Refer to Fig. 4
^ Pressing on, Refer to Fig. 8
9. Thrust washer
10. Taper roller bearing outer race Pressing out , Refer to Fig. 10
^ Pressing in, Refer to Fig. 11
11. Shim
^ Determining thickness - Adjusting input shaft, Refer to Overhaul Subassemblies, Input Shaft Adjusting
12. Transmission housing
13. Sleeve
^ For needle roller bearing
^ Press off with 4th gear and taper roller bearing inner race, Refer to Fig 4
^ Pressing on, Refer to Fig 9
^ Place thrust washer on before installing (item 9)
14. Needle roller bearing 15 5th gear
^ Pull off together with 5th gear synchro - hub - from, Refer to Transmission disassembly and Assembly, Assembly Sequence
16. 5th gear synchro - ring
17. Spring
18. Lock pieces (city. 3)
^ Installation position, Refer to Fig. 12
19. 5th gear synchro - hub
20. 5th gear locking collar
21. Dished washer





Fig. 1 Pressing out taper roller bearing outer race





Fig. 2 Pressing in taper roller bearing outer race





Fig. 3 Pressing on taper roller bearing inner race





Fig. 4 Pressing off 4th gear with taper roller bearing and sleeve





Fig. 5 Pressing off 3rd gear





Fig. 6 Pressing on 3rd gear





Fig. 7 Pressing on 4th gear
- Shoulder points to 3rd gear.





Fig. 8 Pressing on taper roller bearing inner race





Fig. 9 Pressing on sleeve for needle roller bearing





Fig. 10 Pressing out taper roller bearing outer race





Fig. 11 Pressing in taper roller bearing outer race
- Install with shim after adjusting input shaft.





Fig. 12 5th gear synchronizer
1. Springs for lock pieces
2. Locking collar with 3 recesses (arrows A) for the locking pieces (item 4)
3. Synchro - hub
4. locking pieces Installation position: the thin extension (arrow B) faces the point - teeth of the locking collar (item 2)





Fig. 13 Assembling 5th gear locking collar/synchro - hub
- Push locking collar over synchro - hub.
- Pointed teeth - A - and shoulder - B - of synchro - hub face in same direction. The recesses for the locking pieces in locking collar and synchro - hub must be aligned (Fig 12).
- Insert locking pieces (installation position: Fig. 12).
- Insert springs offset by 120� underneath lug - C -. The angled ends of the spring must be directly behind the locking pieces (arrows).