Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling
Special tools and workshop equipment required
- VW 295 Drift
- VW 295 A Adapter
- VW 401 Press plate
- VW 402 Press plate
- VW 407 Press tool
- VW 408 A Press tool
- VW 415A Tube
- VW 416B Tube
- VW 447 Thrust plate
- VW 771 Multipurpose tool
- 30-100 Drift sleeve
- 40-105 Thrust plate
- VW 222 A Drift
- 30-24 Drift
- 40-202 Press piece
- 1 - Kukko 21/4 Internal puller
- 3 - Kukko 17/2 Separating device
Notes:
- When installing new gear wheels or the input shaft, consult technical data.
- If parts are exchanged which will affect the position of the ball bearings, the input shaft must be readjusted
1. Circlip
- Installation position see Fig. 11 item 1
2. Ball bearing
3. Securing clip
- Installation position see Fig. 11 item 2
4. Transmission housing
5. Needle roller bearing
- Removing see Fig. 1
- Installation position see Fig. 2
- Pressing in see Fig. 3
6. Input shaft
- With lubricating sleeve
- Driving in lubricating sleeve see Fig. 16
7. Needle roller bearing
- For 3rd gear
8. 3rd gear wheel
9. Spring
- Insert in 3rd gear wheel see Fig. 9
- Allocate to gear wheel from the parts catalog
10. 3rd gear synchro-ring
- Checking for wear see Fig. 10
- Installation position see Fig. 11 item 3
11. Securing clip
- Installation position see Fig. 11 item 4
12. 3rd and 4th gear synchrohub
- Shoulder faces to 3rd gear
- Pressing off see Fig. 8
- Pressing on see Fig. 13
13. Securing clip
- Installation position see Fig. 11 item 4
- If the synchro hub is replaced redetermine thickness see Fig. 12
14. 3rd and 4th gear locking collar
- Installation position see Fig. 14
15. 4th gear synchro-ring
- Checking for wear see Fig. 10
16. Spring
- Insert in 4th gear wheel see Fig. 9
- Allocate to gear wheel from the parts catalog
17. 4th gear wheel
18. Needle roller bearing
- For 4th gear
19. 5th gear wheel
- Pressing off see Fig. 7
- Pressing on see Fig. 15
20. Securing clip
- Installation position see Fig. 11, item 5
- If the 5th gear wheel is replaced redetermine thickness see Fig. 12
21. Roller sleeve
- Always replace
- Will be damaged when removing
- Pulling out see Fig. 4
- Installation position see Fig. 5
- Driving in see Fig. 6
22. Sleeve
- Made of plastic
23. Transmission cover
Fig. 1 Driving out needle bearing.
Fig. 2 Installation position of needle bearing
Dimension "a" from lower edge of straight edge to upper edge of needle roller bearing = 39.5 mm
Fig. 3 Pressing in needle bearing
Fig. 4 Pulling out roller sleeve
A- Internal extractor, e.g. Kukko 21/4, 22 to 28 mm
- Before fitting internal extractor the plastic sleeve inside the roller sleeve must be destroyed.
Fig. 5 Installation position of roller sleeve
Dimension a = 216 mm
Fig. 6 Driving in roller sleeve
Fig. 7 Pressing off 5th gear wheel
A - Separating device 22 to 1 15 mm, e.g. Kukko 1 7/2
Fig. 8 Pressing off 3rd and 4th gear synchro hub
- Press 3rd gear synchro ring (arrow) towards 3rd gear wheel, then fit separating device -A-.
A - Separating device 22 to 115 mm, e.g. Kukko 1 7/2
Fig. 9 Inserting spring in gear wheel
The bent end of the spring (arrow) must be hooked into the hole in the gear wheel.
Fig. 10 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-.
- Calculate average gap.
The average gap must not be less than 0.5 mm.
Fig. 11 Position of circlips
- The circlips -1- and -2- secure the input shaft ball bearing.
- The circlip -3- secures the 3rd and 4th gear synchro hub.
It is always 2 mm thick
Identification: Color- brown
- The circlip -4- secures the 3rd and 4th gear synchro hub.
Identification: Color- blue
- The circlip -5- secures the 5th gear wheel.
Fig. 12 Determining thickness of circlip
- Determine the thickest circlip, which will just fit and install it.
- Determine circlip as precisely as possible using table.
Note: Allocate circlip according to parts catalog.
Circlips available for 3rd and 4th gear synchronizing hub
Circlips available for 5th gear wheel
Fig. 13 Pressing on 3rd and 4th gear synchro-hub
Higher collar faces 3rd gear.
Fig. 14 Installation position of locking collar
Locking collars with chamfer (illustration A, arrow 1) as well as locking collars with deep shoulder (illustration B. arrow 3) are fitted.
Installation position:
The chamfer (arrow -1-) faces 4th gear.
Shallow shoulder (arrow -2-) faces 3rd gear.
Deep shoulder (arrow 3) faces 4th gear.
Fig. 15 Pressing on 5th gear wheel
The higher collar faces to reverse gear
Fig. 16 Driving lubrication sleeve into input shaft
Note: Allocate lubrication sleeve to input shaft according to parts catalog.
- Installation position: beaded-over edge of lubrication sleeve faces drift
- Installation depth: 3.5 mm below upper edge