Input Shaft

Input Shaft

=> [ Grooved Ball Bearing Changes ]

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Thrust Disc (VW 412)

• Thrust Pad 16.5/28 mm Dia. (VW 431)

• Arbor 50 mm dia. (VW 432)

• Thrust Tube (VW 454)

• Locking Pin (30-505)

• Thrust Piece (40-105)

• Press Tube (2040)

• Kukko Extractor (21/5)

• Kukko Puller 65-160 mm (18/1)

• Kukko Separating Tool 12-75 mm (17/1)

• Kukko Separating Tool 22-115 mm (17/2)

• Kukko Support (22/2)

Disassembly

- Remove the grooved ball bearing locking ring.

Removing the Grooved Ball Bearing





- Beforehand, remove the circlip from the input shaft.

- Before attaching the extractor, place the (VW 431) and the (40-105) on the input shaft.

- Attach the separating device - B - into the surrounding groove for the circlip in the bearing.

A Extractor, for example, (18/1)
B Separating device 12 to 75 mm, for example, (17/1)

Removing the 5th Gear Wheel





A Separating device 22 to 115 mm, for example, (17/2)

Assembly

Installing 5th Gear Wheel





The groove - arrow - on the gear wheel must point upward.

Grooved Ball Bearing Installed Position





The groove for the circlip points upward - arrow A - and the shoulder - arrow B - must point toward the 5th gear wheel

Pressing on Grooved Ball Bearing





Grooved ball bearing with a rubber ring - arrow -

The shoulder - A - faces the (VW 412).

- Install the grooved ball bearing locking ring on the input shaft (=> next illustration).

Determining the Grooved Ball Bearing Locking Ring on the Input Shaft





- Insert a 1.86 mm thick circlip - A - into the groove of the input shaft and press upward.

- Measure the dimension between the grooved ball bearing - B - and the installed circlip - A - using a feeler gauge - C -.

- Remove the circlip inserted for the measurement.

- Determine the circlip according to the table.

The following circlips are available:





Pulling Cylindrical Roller Bearing off Clutch Housing





- When pulling off the circlip - arrow - for the cylindrical roller bearing, compress using pliers - C -.

A Support, for example, (22/2)
B Internal puller 30 to 37 mm, for example, (21/5)

Pressing Cylindrical Roller Bearing into Clutch Housing





- When pressing in the circlip - arrow - for the cylindrical roller bearing, compress using pliers - A -.

- Remove the pliers before the cylindrical roller bearing is in the installed position. Circlip must engage into the groove of the clutch housing.

Grooved Ball Bearing Changes

From transmission build date 10 April 2006 through approximately 21 January 2008

A washer above and below the grooved ball bearing seat - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.

Above the Bearing Seat:









Below the bearing seat - arrow -:

Slightly deeper from transmission build date 10 April 2006 through approximately 21 January 2008





The grooved ball bearing seat - arrow - is slightly deeper to hold the washer under the bearing - item 6 -=> [ Grooved Ball Bearing ] Input Shaft Overview.





Flattened areas on the grooved ball bearing - A - and bearing seat - B - in the transmission housing approximately from transmission build date 21 January 2008





• If the flattened areas are present, do not insert any washers above and below the grooved ball bearing.