Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling, 01A, 5 SPD. M/T (AWD)
Special tools, testers and auxiliary items required:
^ Drift VW 295
^ Adapter VW 295 A
^ Pressure plate VW 401
^ Pressure plate VW 402
^ Punch VW 407
^ Punch VW 408 A
Special tools, testers and auxiliary items required:
^ Tube VW 415 A
^ Tube VW 416 B
^ Thrust pad VW 447 i
^ Slide hammer VW 771
^ Press Tube 30-100
^ Thrust piece 40 - 105
Special tools, testers and auxiliary items required:
^ Drift VW 222 A
^ Drift 30 - 24
^ Press off piece 40 - 202
^ - 1 - Internal extractor Kukko 21/4
^ - 3 - Separating tool Kukko 17/2
Note:
^ As of transmission manufacture date 23 06 3, a new synchronization for 3rd and 4th gears has been implemented.
^ When installing new gear wheels or input shaft, note Technical Data.
1. Circlip
^ Identification
^ Installation position, - item 1 -
2. Ball bearing
3. Circlip
^ Identification
^ Installation position, - item 2 -
^ Determining thickness
4. Transmission housing
5. Needle bearing
^ Secured with bolt
^ Driving out
^ Note allocation of input shaft/needle bearing
^ Installation position
^ Pressing in
6. Input shaft
^ With oiling sleeve
^ Driving in oiling sleeve
^ Note allocation of input shaft/needle bearing
7. Needle bearing for 3rd gear
^ Identification
8. 3rd gear sliding gear
^ As of transmission manufacture date 23 06 3, modified synchronization
9. Spring
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Inserting in 3rd gear sliding gear
10. Synchronizer ring for 3rd gear
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Checking for wear
11. Circlip
^ Identification
^ Installation position, - item 3 -
12. Synchronizer hub for 3rd and 4th gears
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Shoulder faces third gear
^ Pressing off
^ Pressing on
13. Circlip
^ Identification
^ Installation position, - item 4 -
^ Re-determining thickness when replacing synchronizer body
14. Sliding sleeve for 3rd and 4th gears
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Installation position up to transmission manufacture date 22 06 3
^ Installation position as of transmission manufacture date 23 06 3
15. Synchronizer ring for 4th gear
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Checking for wear
16. Spring
^ As of transmission manufacture date 23 06 3, modified synchronization
^ Inserting in 4th gear sliding gear
^ Allocation to sliding gear Electronic Parts Catalog (ETKA)
17. 4th gear sliding gear
^ As of transmission manufacture date 23 06 3, modified synchronization
18. Needle bearing for 4th gear
^ Identification
19. 5th-gear gear wheel
^ Pressing off
^ Pressing on
20. Circlip
^ Identification
^ Installation position, - item 5 -
^ If 5th-gear gear wheel is replaced, re-determine thickness of circlip
21. Roller sleeve
^ Replace
^ Damaged when removed
^ Pulling out
^ Installation position
^ Driving in
22. Sleeve
^ Made of plastic
23. Transmission cover
^ Coat sealing surfaces thinly with sealant AMV 188 00102
Securing bolt - arrow - for needle bearing
^ Remove securing bolt - arrow -.
Note:
^ Bolt is not installed on aft construction versions.
Driving out needle bearing
Allocation of input shaft/needle bearing
Note: In order to avoid damage due to improper assembly, check the following after replacing the input shaft.
^ Input shaft must be able to be guided in
^ Input shaft must have no play.
Installation position of needle bearing
Dimension - a - from lower edge of straight-edge to upper edge of needle bearing = 39.5 mm
Note: Measure the dimension from the top edge of the straight-edge and subtract the height of the straight-edge from the measured dimension.
Pressing in needle bearing
^ If present, screw in securing bolt for needle bearing and tighten it to 25 Nm.
Driving in oiling sleeve into input shaft
Installation position: Flared edge of oil sleeve faces installation tool
^ Installation depth
3.5 mm under below upper edge
Pulling out roller sleeve
A - Internal puller 22 to 28 mm, e.g. Kukko 21/4
^ Plastic sleeve inside roller sleeve must be destroyed to install internal puller.
Installed position of roller sleeve
^ Dimension - a - = 216 mm
Driving in roller sleeve
Pressing off 5th-gear gear wheel
^ Remove circlip before pressing off.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing off synchronizer hub for 3rd and 4th gears
^ Remove circlip before pressing off.
^ Set separating device - A - under 3rd gear sliding gear. Press off synchronizer hub with 3rd gear sliding gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Inserting spring into 4th gear sliding gear
The bent end of spring - arrow - must be hooked into hole of sliding gear.
Checking synchronizer ring for wear
^ Press synchronizer ring into sliding sleeve and measure gap dimension - a - at positions - A -, - B - and - C - using a feeler gauge.
^ Add measured values and divide total by three to calculate average.
Determined value must not exceed 0.45 mm.
Installation position of circlips
^ Circlips - 1 - and - 2 - secure input shaft ball bearing.
Determining thickness.
^ Circlip - 3 - secures synchronizer hub 3rd and 4th gear.
Thickness 2.00 mm. Characteristic: brown color
^ Circlip - 4 - secures synchronizer hub 3rd and 4th gear.
Determining thickness Characteristic: blue color
^ Circlip - 5 - secures 5th-gear gear wheel
Determining thickness.
Determining circlip
^ Determine thickest circlip which can still just be installed and insert.
^ Determine circlip according to table. Part numbers Electronic Parts Catalog (ETKA)
The following circlips are available for synchronizer hub for 3rd and 4th gear
The following circlips are available for synchronizer hub for 5th-gear gear wheel
Pressing on synchronizer hub for 3rd and 4th gears
^ Installation position:
High inner collar faces 3rd gear
Installation position of sliding sleeve up to 05.03
Sliding sleeves with chamfer, figure - A arrow 1 - as well as sliding sleeves with large offset, figure - B arrow 3 - are installed.
^ Installation position:
Chamfer - arrow 1 - faces 4th gear.
Small offset - arrow 2 - faces 3rd gear
Large offset - arrow 3 - faces 4th gear
Installation position of sliding sleeve as of transmission manufacture date 23 06 3
Groove - arrow - faces 3rd gear sliding gear.
Pressing on 5th-gear gear wheel
CAUTION: Wear protective gloves!
^ Heat 5th-gear gear wheel to approximately 100° before pressing on.
^ Installation position: Higher collar points to reverse gear