Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling, 01E, 6 Spd. M/T AWD
Special tools and equipment:
^ VW 401 Thrust plate
^ VW 412 Thrust tool
^ VW 519 Tube
^ Feeler gauge
Note:
^ When installing new gears or the input shaft consult technical data
1 - Transmission housing
^ Servicing
2 - Needle bearing
^ For input shaft
^ Pulling out, go to Fig. 13
^ Driving in, go to Fig. 14
3 - Circlip
^ For needle bearing
4 - Circlip
^ For input shaft
5 - Thrust washer
6 - Needle bearing
^ For 5th gear
^ Mark before removing
^ Do not interchange with needle bearing for 3rd gear
^ Oil with gear oil before installing
7 - 4th sliding gear
^ Before installing, insert spring go to Fig. 1
8 - 4th gear synchro-ring
^ Checking for wear go to Fig. 2
9 - Locking collar
^ Paired with synchro-hub
^ Mark before removing
10 - Circlip
^ When replacing synchro-hub, re-determine thickness go to Fig. 3
^ Installation position: Ends align with groove of synchro-hub
11 - Synchro-hub for 3rd and 4th gear
^ Pressing off go to Fig. 4
^ Installation position go to Fig. 5
^ Pressing on go to Fig. 6
12 - 3rd gear synchro-ring
^ Coated with molybdenum
^ Checking for wear go to Fig. 2
13 - 3rd sliding gear
^ Before installing, insert spring go to Fig. 1
^ After pressing on -item 11 - check axial play using feeler gauge (0.15 to 0.35 mm)
14 - Needle bearing
^ For 3rd gear
^ Mark before removing
^ Do not interchange with needle bearing for 4th gear
^ Lubricate with gear oil before installing
15 - Input shaft
16 - Spring pin
^ Replace
^ Drive in when replacing input shaft go to Fig. 7
17 - Cylindrical roller bearing
^ For input shaft
^ Pressing out, go to Fig. 5
^ Pressing in, go to Fig. 6
18 - Bearing plate
^ Servicing
19 - Inner race
^ For cylinder roller bearing
^ Remove and install by hand
20 - Circlip
21 - Thrust washer
^ For needle bearing for 6th sliding gear
^ Installation position: Shoulder toward circlip, smooth face contact surface toward needle bearing
22 - Needle bearing
^ For 6th gear
^ Oil with gear oil before installing
23 - 6th sliding gear
^ Before installing, insert spring go to Fig. 1
^ After installing, check axial play
24 - 6th gear synchro-ring
^ Checking for wear go to Fig. 2
25 - Synchro-hub for 5th and 6th gear
^ Pulling off
^ Driving on6
^ Installation position: Projecting hub toward 5th sliding gear
26 - Locking collar
^ Paired with synchro-hub
^ Mark before removing
27 - 5th gear synchro-ring
^ Checking for wear go to Fig. 2
28 - 5th sliding gear
^ Before installing, insert spring go to Fig. 1
^ After installing, check axial play
29 - Inner race for needle bearing
^ For 5th sliding gear
^ Pulling off
^ Driving on
30 - Needle bearing
^ For 5th gear
^ Oil with gear oil before installing
31 - 1st inner race for four-point bearing
^ Ball bearing side
^ Pulling off
^ Driving on
32 - End cover
^ Servicing
33 - 2nd inner race for ball bearing
^ Pulling off
^ Driving on
34 - Multi-point socket head bolt, 150 Nm
^ Loosening
^ Tightening
Fig. 1 Inserting spring in sliding gear
The bent end of the spring (arrow) must be hooked in the hole in the sliding gear.
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 the measured values and divide by 3.
^ The calculated value must not be less than 0.5 mm.
Fig. 3 Determining thickness of circlip
^ Synchro-hub pressed onto stop
- Determine the thickest circlip that will just fit and install it.
Note: The opening of circlip must align with groove in synchro-hub.
Allocate circlip using spare part catalog.
The following circlips are available:
Fig. 4 Pressing off synchro hub for 3rd and 4th gear
Fig. 5 Installation position of synchro-hub
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, position and press home.
WARNING! Wear protective gloves!
- Determine circlip and install go to Fig. 3.
Fig. 7 Driving spring sleeve into input shaft
- Guide a 9 mm diameter drift -A- into oil drilling and drive spring sleeve -B- in until it touches drift.