Input Shaft
Input Shaft
Special tools, testers and auxiliary items required
• Driving Sleeve (VW 244 B)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 407)
• Thrust Disc (VW 412)
• Arbor (VW 434)
• Thrust Tube (VW 454)
• Thrust Tube (VW 455)
• Sleeve (VW 519)
• Sleeve (40 - 21)
• Support Bridge (2011)
• Tube for Wheel Bearing (3345)
• - 3 - Separating Tool (Kukko 17/2)
• Inductive Heater (VAS 6414)
• Depth Gauge
Input shaft, 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 Assembly Overview ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts Assembly Overview.
• The bolt inside the input shaft is removed => [ If it is necessary to disassemble the input
shaft, then the bolt in the shaft must be removed now
using, for example, a torque wrench. ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts.
- Remove the 3rd, 4th and 6th gearshift wheels together with the 3rd and 4th gear synchronizer hubs and the inner race / needle bearing.
A Separating device 22 to 115 mm, for example (Kukko 17/2)
• Support the separating tool - A - on the 6th gear wheel in such a way so that the 5th/6th gear locking collar will not get pulled off.
- Remove the locking ring on the 5th/6th gear synchronizer hub from the input shaft.
• Mark the locking ring so that it does not get confused with the locking ring underneath the 5th/6th gear synchronizer hub.
- Remove the 5th and 6th gear synchronizer hub/locking collar with the 5th gear wheel.
- Expand the 5th gear needle bearing - 2 - and carefully guide it over the locking ring - 1 - as well over the splines - 3 - on the 5th/6th gear synchronizer hub.
• Remove the locking ring - 1 - underneath the splines - 3 - on the 5th/6th gear synchronizer hub from the input shaft if the roller bearing is being replaced.
• Always replace after removing.
- Remove the locking ring - 1 -.
- Press roller bearing off input shaft.
A Separating device 22 to 115 mm, for example (Kukko 17/2)
• The roller bearing will get damaged when it is being removed, therefore always replace it.
• The roller bearing cage can also get damaged when removing using a screwdriver. Then mount the separating tool on the inner race.
- Clean the bolt threads on input shaft from locking compound residue.
Input shaft, 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 130 °C (2166 °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.
Inserting Spring into Selector Gear
The bent end of the spring - arrow - must be hooked into the hole in the selector gear.
Checking Synchronizer Ring for Wear
- Press the synchronizer ring - E - into the locking collar and then measure the gap dimension - a - using a depth gauge - D - at - A -, - B - and - C -.
- Add measured values and divide by 3.
Determined value must not exceed 0.5 mm.
• If the components are not to be replaced, make sure they are reallocated to their original gear.
- Install the roller bearing all the way onto the input shaft.
- Carefully expand the new locking ring - 1 - guide it over the splines on the 5th/6th gear synchronizer hub - 3 -.
• The locking ring must not be turned by hand in the groove all around the input shaft
- Expand the needle bearing - 2 - on the 5th gear wheel and carefully guide id over the locking ring - 1 -. When doing this, do not lay the needle bearing on the collar - arrow - on the input shaft.
- Install the 5th gear wheel - B -.
• The gear wheel - B - must not touch the locking ring - A - while it is being turned.
• There must be an even distance - x - between the gear wheel and the locking ring.
- Install the 5th gear synchronizer ring.
Installed Position: Locking Collar and 5th/6th Gear Synchronizer Hub
• The shorter spline - arrow A - above the groove - arrow B - on the synchronizer hub - 1 - must be facing the 6th gear wheel.
• The groove - arrow C - on the front of the locking collar - 2 - must be facing the 6th gear.
- Slide the locking collar - 2 - over the synchronizer hub - 1 -.
Note the follow when performing the next steps:
- Insert the input shaft into the hole in the (2011).
- 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.
Pressing on synchronizer hub with locking collar for 5th and 6th gears
Determining the 5th and 6th gear synchronizer hub locking ring
• The synchronizer hub is installed all the way.
- Determine thickest circlip which can still just be installed and insert it. For the part number, refer to the electronic parts catalog ETKA
The following locking rings are available:
- Install the 6th gear wheel, the needle bearing and the synchronizer ring.
- Install the thrust washer - A -.
- Install the 3rd gear wheel inner race / needle bearing - B -.
- Install the 3rd gear wheel, the needle bearing and the synchronizer ring.
Installed Position: Locking Collar and 3rd/4th Gear Synchronizer Hub
• The inside collar - arrow A - on the synchronizer hub faces 4th gear.
• The groove - arrow B - on the front of the locking collar - 2 - must be facing the 4th gear.
- Slide the locking collar - 2 - over the synchronizer hub - 1 -.
Pressing on Synchronizer Hub with Locking Collar for 3rd and 4th Gears
Installing the 4th Gear Wheel Inner Race / Needle Bearing - A -
- Install the 4th gear wheel, the needle bearing and the synchronizer ring.
- Install the thrust washer - A -.
- Install the roller sleeve inner race - B -.
- Then check all selector gears for ease of movement and axial play.
• Selector gear axial play must be at least 0.15 mm.
• Tighten the input shaft bolt to the tightening specification => [ The bolt inside the
input shaft must be tightened now with a torque wrench to
the tightening specification ] Shift Fork Group, Input Shaft, 1st, 2nd and Reverse Gear Output Shafts.