Input Shaft, Disassembling and Assembling
Input shaft (transmission as of approx. 04.2003), disassembling and assembling, 02M/02Y, 5 & 6 Speed M/T, AWD
Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust plate VW 402
^ Punch VW 407
^ Punch VW 412
^ Thrust Pad 16.5/28 mm Dia. VW431
^ Arbor 50 mm Dia. VW432
Special tools, testers and auxiliary items required
^ Thrust tube VW 454
^ Thrust piece 30-505
^ Thrust piece 40-105
^ Press tube 2040
^ - 1 - Internal extractor Kukko 21/5
^ - 2 - Puller Kukko 18/1
^ - 3 - Separating tool Kukko 17/1 and Kukko 17/2
^ - 4 - Support Kukko 22/2
Input shaft, assembly overview
Note: Lubricate all bearings with gear oil when inserting on input shaft.
1 - Circlip
^ When replacing tapered roller bearing and input shaft, determine again
2 - Transmission housing
3 - Circlip
4 - Grooved ball bearing
^ Pulling off
^ Pressing on
5 - Gear wheel for 5th gear
^ Pressing off
^ Pressing on
6 - Input shaft
^ With gear wheel for 3rd/4th and 6th gears
7 - Cylindrical roller bearing
^ With circlip
^ Pulling out
^ Pressing in
^ Installed position: Circlip in bearing points to input shaft
8 - Clutch housing
Pulling off grooved ball bearing
- First remove seal.
- Before attaching extractor, place Thrust pad VW 431 and thrust piece 40-105 on input shaft.
- Attach separating device - B - into surrounding groove for circlip in bearing.
A - Puller Kukko 18/1
B - Separating tool 12 to 75 mm Kukko 17/1
Pressing off 5th gear
A - Separating tool 22 to 115 mm Kukko 17/2
Pressing on 5th gear
^ Groove - arrow - on gear wheel must point upward.
Pressing on grooved ball bearing
- Determine circlip and install.
^ Installed position grooved ball bearing: Groove for circlip points upward - arrow A - and shoulder - arrow B - must point toward gear for 5th gear.
Determining circlip
- Insert a 1.86 mm thick circlip - A - into groove of input shaft and press upward.
- Measure dimension between grooved ball bearing - B - and installed circlip - A - using a feeler gauge - C -.
- Remove circlip inserted for measurement.
- Determine exact shim thickness on the basis of the following table.
The following circlips are available:
Pulling cylindrical roller bearing off clutch housing
- When pulling off, press together seal - arrow - of cylindrical roller bearing using pliers - C -.
A - Support Kukko 22/2
B - Internal puller 30 to 37 mm Kukko 21/5
Pressing cylindrical roller bearing into clutch housing
- When pressing in, press together seal - arrow - of cylindrical roller bearing using pliers - A -.
- Remove pliers before cylindrical roller bearing is in installed position.
^ Circlip must engage into groove of clutch housing.