Input Gear, Removing and Installing

Input gear, removing and installing

Required special tools and equipment:








^ VW 402 Press plate
^ VW 407 Press tool
^ VW 771 Multi-purpose tool
^ 30-205 Thrust plate
^ 40-21 Press tool
^ 40-105 Thrust plate
^ V.A.G 1582 Taper roller bearing puller
^ V.A.G 1582/3 Grip
^ V.A.G 1576 Torque wrench or similar

Note:
Drive pinion and differential do riot need to be removed,
Measure friction torque at drive pinion nut before removing input gear.





1 Socket head fastener, 250 Nm (184 ft. lbs.)
^ Engage parking lock to remove and install
^ Use 22 mm socket
^ Before installing socket head fastener, insert axial needle bearing (item 7)
2 Dished washer
^ Curved side faces socket head fastener
3 Shim
^ Determining thickness
4 Taper roller bearing inner race After measuring thickness of shim, install on input gear with locking fluid AMV 185 101 A1 refer to Fig. 3
5 Taper roller bearing outer race
^ Drive out with drift
^ Drive in with 30-205
^ Insert with locking fluid AMV 185 101 A1
6 Transmission housing
7 Axial needle bearing
^ Install with flat side facing input gear
^ Insert into input gear before installing socket head fastener (item 1)
8 Taper roller bearing outer race
^ Drive out with drift
^ Drive in with 30-205 and long enough drift
^ Insert with locking fluid AMV 185 101 A1
9 Taper roller bearing inner race
^ Pulling off refer to Fig. 1
^ Pressing on refer to Fig. 2
^ Insert with locking fluid AMV 185 101 A1 refer to Fig. 3
10 input gear
^ With impulse wheel for Vehicle Speed Sensor (VSS) -G68-
^ Number of teeth.
^ Adjusting.
^ If input gear is damaged, always replace input gear and output gear together
^ Removing refer to Fig. 4
^ If you replace input gear, adjust planet carrier.





Fig. 1 Taper roller bearing inner race, removing
^ Place thrust plate 40-105 on input gear.





Fig. 2 Taper roller bearing inner race. installing

CAUTION!
Place a press piece below the hub of the input gear to avoid damaging the input gear.





Fig. 3 Taper roller bearing inner race, inserting
^ Insert taper roller bearing inner race -arrow- with AMV 185 101 A1





Fig. 4 Input gear, removing
^ Insert socket head fastener without dished washer, shim and axle needle bearing far enough until you have a gap a = 3 mm between socket head fastener and taper roller bearing inner race.
^ Drive out input gear with VW 771 to stop of taper roller bearing inner race.
^ Remove VW 771 and take out input gear.