Input Shaft, Disassembling and Assembling
Input shaft, disassembling and assembling, 012/01W, 5 SPD. M/T
Special tools, testers and auxiliary items required:
^ Needle Bearing Drift VW 295
^ Adapter VW 295 A
^ Thrust Plate VW 401
^ Thrust 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-Complete Set VW 771
^ Fitting Sleeve 30 - 100
^ Thrust piece 40 - 105
Special tools, testers and auxiliary items required:
^ Mandrel VW 222 A
^ Mandrel 30 - 24
^ Press 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 gear is applied.
^ When installing new gears or input shaft, observe technical data.
1. Circlip
^ Identification
^ Installed position - item 1 -
2. Ball bearing
3. Circlip
^ Identification
^ Installed position - item 2 -
4. Transmission housing
5. Needle bearing
^ Secured with bolt
^ Driving out
^ Installed position
^ Pressing in
^ Securing
6. Input shaft
^ With oiling sleeve
^ Pressing in oiling sleeve
7. Needle bearing for 3rd gear
^ Identification
8. 3rd gear
^ Modified synchronization as of transmission manufacture date 23 06 3 Modified synchronization 3rd and 4th gear as of transmission manufacture date 23 06 3
9. Spring
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Inserting in 3rd gear
^ Application of spring to gear Electronic Parts Catalog (ETKA)
10. Synchronizer ring for 3rd gear
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Checking for wear
11. Circlip
^ Identification
^ Installed position - item 3 -
12. Synchronizer hub for 3rd and 4th gears
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Shoulder faces third gear
^ Pressing off
^ Pressing on
13. Circlip
^ Identification
^ Installed position - item 4 -
^ Re-determining thickness when replacing synchronizer body
14. Operating sleeve for 3rd and 4th gears
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Installed position up to transmission manufacture date 22 06 3
^ Installed position as of transmission manufacture date 23 06 3
15. Synchronizer ring for 4th gear
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Checking for wear
16. Spring
^ Modified synchronization as of transmission manufacture date 23 06 3
^ Inserting in 4th gear
17. 4th gear
^ Modified synchronization as of transmission manufacture date 23 06 3 Modified synchronization 3rd and 4th gear as of transmission manufacture date 23 06 3
18. Needle bearing for 4th gear
^ Identification
19. 5th gear
^ Pressing off
^ Pressing on
20. Circlip
^ Identification
^ Installed position - item 5 -
^ If 5th gear is replaced, re-determine thickness of circlip
21. Roller sleeve
^ Replace
^ Damaged when removed
^ Pulling out
^ Installed position
^ Driving in
22. Sleeve
^ Made of plastic
23. Transmission cover
^ Made out of aluminum, may only be installed with transmission housing made out of aluminum
^ Made out of magnesium, may only be installed with transmission housing made out of magnesium
^ Note identification
^ Coat sealing surfaces with a thin layer of sealant AMV 188 001 02
Remove securing bolt - arrow - for needle bearing
^ Remove securing bolt - arrow
Note:
^ Bolt is not installed on aft construction versions.
Driving out needle bearing
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
Screw in securing bolt - arrow -
Note:
^ Bolt is not installed on aft construction versions.
^ Transmission housing made out of aluminum 25 Nm
^ Transmission housing made out of magnesium 20 Nm
Driving in oiling sleeve into input shaft
Installed position: Flared edge of oil sleeve faces installation tool
^ Installation depth: 3.5 mm under below upper edge
Remove roller sleeve
A - Internal puller 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
^ 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.
^ Place separating device - A - beneath 3rd gear. Press off synchronizer hub with 3rd gear.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Inserting spring into gear
The bent end of spring - arrow - must be hooked into hole of shift gear.
Checking synchronizer ring for 3rd and 4th gears for wear
^ Press synchronizer ring into operating sleeve and measure gap dimension - a - using a feeler gauge at positions - A, B and - C -.
^ Add measured values and divide total by three to calculate average.
Determined value must not be more than 0.45 mm.
Installation position of circlips
^ Circlips - 1 - and - 2 - secure the input shaft ball bearing.
^ Circlip - 3 - secures the synchronizer hub 3rd and 4th gear.
Thickness 2.00 mm. Characteristic: brown color
^ Circlip - 4 -secures the synchronizer hub 3rd and 4th gear.
Determining thickness. Characteristic: blue color
^ Circlip - 5 - secures the 5th gear.
Determining thickness.
Determining circlip
^ Determine thickest circlip which can still just be installed - and insert.
^ Determine circlip according to table.
The following circlips are available for synchronizer hub for 3rd and 4th gear
The following circlips are available for synchronizer hub for 5th gear
Press on synchronizer hub for 3rd and 4th gears
^ Installed position:
Higher inner collar faces 3rd gear
Installed position of operating sleeve up to transmission manufacture date 22 06 3
Operating sleeves with chamfer - A arrow 1 - as well as operating sleeves with large offset - B arrow - 3 - are installed.
^ Installed position:
Chamfer - arrow 1 - faces 4th gear.
Small offset - arrow 2 - faces 3rd gear.
Small offset - arrow 3 - faces 3rd gear.
Installed position of operating sleeve as of transmission manufacture date 23 06 3
Groove - arrow - faces 3rd gear.
Pressing on 5th gear
CAUTION: Wear protective gloves!
^ Heat 5th gear to approximately 100 T before pressing on.
^ Installed position:
Shoulder faces reverse gear