Input Shaft, Disassembling and Assembling

Input shaft, disassembling and assembling





Special tools and equipment
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW408A punch
^ VW412 thrust disc
^ VW416B tube





Special tools and equipment
^ VW309 holding plate
^ VW353 transmission support
^ VW433 thrust pad
^ VW454 thrust tube
^ VW 457 support channels
^ VW 801 holding fixture





Special tools and equipment
^ 40 105 thrust piece
^ 41 501 mounting sleeve
^ 2040 press tube
^ 2050 thrust plate
^ 3074 pressure disc
^ 3161 attachment piece





Special tools and equipment
^ 3235 press device
^ VAG 1582 taper roller bearing puller
^ VAG1582/7 attachment to VAG1582
^ 1 Kukko 21/7 extractor
^ 3 Kukko 17/2 separating tool
^ 4 Kukko 22/2 support

Notes:
^ Observe technical information when installing new pinion gear.
^ If the installation position of the tapered roller bearing is influenced by replacement of parts, the input shaft must be adjusted again. Observe installation overview, Refer to Differential Assembly, Adjustments





1. Transmission housing
2. Adjustment shim
^ Determining thickness, Refer to Subassemblies Overhaul, Input Shaft Adjusting
3. Tapered roller bearing outer race
^ Pulling out, Refer to Fig 1
^ Pressing in, Refer to Fig 2
4. Retaining clip
^ During replacement of tapered roller bearing -5- and the input shaft -8- re-determine thickness of circlip, Refer to Fig. 11
5. Tapered roller bearing inner race
^ Removing, Refer to Fig. 3
^ Pressing on, Refer to Fig. 10
6. 5th gear
^ Pressing off, Refer to Fig 4
^ Pressing on, Refer to Fig. 10
7. Pinion 3rd/4th and 6th gear
^ Pressing off, Refer to Fig 5
^ Pressing on, Refer to Fig 7
8. Input shaft
^ Adjusting, Refer to Overhaul Subassembly, Input Shaft Adjusting
9. Tapered roller bearing inner race
^ Pressing off, Refer to Fig. 6
^ Pressing on, Refer to Fig. 8
10. Tapered roller bearing outer race
^ Pulling out, Refer to Fig. 12
^ Installing, Refer to Fig. 13
11. Clutch housing





Fig. 1 Removing tapered roller bearing outer race from transmission housing
A - support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7





Fig. 2 Installing tapered roller bearing outer race in transmission housing
- Support transmission housing with 2050 thrust plate directly below bearing support.





Fig. 3 Remove tapered roller bearing inner race
- Place 3161 attachment piece and 10 105 thrust piece onto input shaft before installing puller.
A - protective jaws for vice





Fig. 4 Pressing off 5th gear
A - separating tool e.g. Kukko 17/2





Fig. 5 Pressing off pinion 3rd/4th and 6th gear





Fig. 6 Pressing off tapered roller bearing inner race
A - Kukko 17/2 separating tool





Fig. 7 Pressing on pinion 3rd/4th and 6th gear
- Heat up pinion to approximately 100°C.
- Press pinion on without stopping so that the heat does not transfer to the input shaft right away.





Fig. 8 Pressing on tapered roller bearing inner race





Fig. 9 Pressing on 5th gear





Fig. 10 Pressing on tapered roller bearing inner race





Fig. 11 Determining thickness of circlip
- Determine and install thickest circlip which can still just be installed.





The following securing clips are available





Fig. 12 Removing tapered roller bearing outer race from clutch housing
A - support, i.e. Kukko 22/2
B - extractor, e.g. Kukko 21/7





Fig. 13 Pressing in tapered roller bearing outer race