Input Shaft
Input Shaft
Special tools, testers and auxiliary items required
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Punch (VW 408 A)
• Thrust Disc (VW 412)
• Thrust Tube (VW 454)
• Tube 60 mm Dia. (VW 415 A)
• Press Tube (2040)
• Press Support (3118)
• Tube (3296)
• Assembly Tool (T40213)
• Shop Press (V.A.G 1290A)
• Inductive Heater (VAS 6414)
• Separating Tool 22 to 115 mm , for example, (Kukko 17/2)
• Feeler Gauge
Disassembling
• The input shaft is removed from the output shaft and the bearing bracket. Refer to => [ Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Overview ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Overview.
- With the driveshaft removed, you will first have to remove the locking ring - A - and the shim - B - behind the ball bearing.
- Place the separating tool - A - underneath the helical-cut gear teeth on the 4th gear selector wheel and remove the ball bearing by pressing on it.
A Separating tool 22 to 115 mm , for example, (Kukko 17/2)
- Remove the synchronizer ring, needle bearing for the 4th gear selector wheel.
- Place the separating tool - A - underneath the helical-cut gear teeth on the 6th gear selector wheel and remove the synchronizer hub in the 3rd/4th gear together with the inner race/needle bearing(s) for the 3rd and 4th gear selector wheels.
A Separating tool 22 to 115 mm , for example, (Kukko 17/2)
- Remove the synchronizer rings and needle bearing(s) for the 6th gear selector wheel. Remove the 5th gear wheel, the 5th and 6th gear synchronizer hub and the inner race/needle bearing for the 6th gear wheel by pressing on them.
- Press roller bearing off input shaft.
A Separating tool 22 to 115 mm , for example, (Kukko 17/2)
• Place the separating tool - A - underneath the housing - B -.
• Place bearing bracket - C - over roller bearing on input shaft so that the rollers are not pressed out of the bearing cage - B -.
• The roller bearing cage can also get damaged when removing it with a screwdriver. Then mount the separating tool - A - on the inner race.
Assembling
• Lubricate all needle bearings and synchronizer rings with transmission fluid before inserting.
• Before pressing needle bearing inner races off, warm to a maximum of 100 °C (212 °F) while wearing protective gloves.
• Warm synchronizer ring before pressing off to a maximum of 100 °C (212 °F) while wearing protective gloves.
• Always press roller bearing, needle bearing inner races and synchronizer body to stop so that selector gears have the recommended axial clearance.
Synchronizer Rings for 3rd to 6th Gears, Checking for Wear
- Check inner race on outer friction surface arrow for scoring or signs of wear; replace if necessary.
- Check synchronizer ring on inner friction surface arrow for scoring or signs of wear, replace if necessary.
- Place inner race, intermediate ring and synchronizer ring on selector gear taper and screw in.
• Screw in means: Turn synchronizer ring approximately one turn while pressing on the ring at the same time.
- Then measure the gap dimension - a - with a feeler gauge.
• Replace inner race, intermediate ring and synchronizer ring for the respective gear together.
Installation Location of Synchronizer Rings for 3rd to 6th Gears
• If the parts are not to be replaced, make sure they are reallocated to their original gear.
- Place inner race - 2 - on selector gear - 1 -.
- Install the intermediate ring - 3 -. The tab - B - must be inserted into the recess - A -.
- Insert the synchronizer ring - 4 -. Guide the tabs - C - through the recess - arrow -.
Note the Following when Performing the Next Steps:
- Place pressing tool in center of warmed components (synchronizer hub and needle bearing inner races).
- After pressing briefly on components, stop and align pressing tool again at center and press to stop.
When pressing on, synchronizer ring tabs and synchronizer hub recesses must align. Raise the gear wheel with the synchronizer ring a little bit so that it locks into the openings on the synchronizer hub.
- Place the plate (T40213/1) and the adapter (T40213/9) on the (V.A.G 1290A) pressing table.
- Install the driveshaft in the adapter (T40213/9).
- Install the roller bearing all the way onto the input shaft.
- Insert 5th gear selector gear together with needle bearing and synchronizer ring.
Assembly of Locking Collar/Synchronizer Hub for 5th and 6th Gear
- Slide the locking collar - 1 - over the synchronizer hub - 2 -.
• The openings - arrow C - for the thrust pieces - 3 - in the synchronizer hub and the notches - arrow D - in locking collar must be centered over one another.
• Installed position: The high inside collar - arrow C - or the notch - arrow D - on the synchronizer hub must face the 5th gear wheel.
- Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches - arrow B - in the locking collar.
Pressing on Synchronizer Hub with Locking Collar for 5th and 6th Gears
Installing the 6th Gear Wheel Inner Race/Needle Bearing - A -
- Insert 6th gear selector gear - A - together with needle bearing and synchronizer rings.
- Place the thrust washer - B - on the 6th gear wheel.
- Inner race/needle bearing - C - for the 3rd gear, pressing on.
- Insert 3rd gear selector gear together with needle bearing and synchronizer rings.
Install the Locking Pieces - A - in the Locking Collar
- Coat the 3 locking pieces - A - with some grease on convex side - arrow 1 -.
- Insert 3 locking pieces with the convex side in the openings in the locking collar.
Assembly of Locking Collar/Synchronizer Hub for 3rd and 4th Gear
• Install the 3 locking pieces - 4 - in the installed position into the locking collar openings - 1 -, refer to => [ Install the Locking Pieces in the Locking Collar ].
• Synchronizer hub installation location: The notch - arrow B - or the "label" must face the 4th gear wheel.
- Place the locking collar - 1 - over the synchronizer hub - 2 - so that the openings on the synchronizer hub - arrow A - are centered over the installed locking pieces in the locking collar.
- Then place thrust pieces - 3 - in synchronizer hub and press thrust pieces into notches - arrow C - in the locking collar.
Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears
Inner Race/Needle Bearing for 4th Gear Selector Gear, Pressing On
- Insert the 4th gear wheel - A - and the needle bearing and synchronizer rings.
- Install the thrust washer - B -.
• Check to make sure that the inner race/needle bearing - D - for the 4th gear wheel is higher than the 4th gear wheel itself - A -.
- Press on the ball bearing - C - until it hits the end stop.
- Then check all selector gears for ease of movement and axial play.
• Selector gear axial play must be at least 0.15 mm.
Determine Shim Thickness - B - as Follows:
- Select the thickest - but still installable - shim from those available as replacement parts - B -, refer to the electronic parts catalog ETKA.
• After you have selected the shim, the locking ring - A - must lie against the groove.