Input Shaft
Input Shaft
Special tools, testers and auxiliary items required
• Punch (VW 407)
• Thrust Pad (VW 447 H)
• Thrust Disc (VW 412)
• Tube Split (VW 422)
• Thrust Plate (VW 401)
• Thrust Plate (VW 402)
• Punch (VW 408 A)
• Tube 28 mm Dia. 100 mm (VW 421)
• Thrust Tube (VW 454)
• Thrust Pad (VW 447 i)
• Thrust Pad (VW 510)
• Mounting Universal Joint (41-501)
• Kukko Separating Tool 12-75 mm (17/1)
• When installing new gears or a new input shaft, refer to => [ Code Letters, Transmission Allocation and Capacities ] Code Letters, Transmission Allocation and Capacities and to the Parts Catalog.
• The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts are replaced. Pay attention to the adjustment overview. Refer to => [ Adjustment Overview ] Adjustment Overview.
1 Clutch Housing
2 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the Outer Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing ].
3 Bearing Inner Race/Taper Roller Bearing
• Removing, refer to => [ Removing the Bearing Inner Race/Taper
Roller Bearing ].
• Installing, refer to => [ Installing the Bearing Inner Race/Taper
Roller Bearing ].
4 Input Shaft
• Adjusting, refer to => [ Input Shaft, Adjusting ] Input Shaft, Adjusting.
5 3rd Gear
• Installed position: The shoulder faces 4th gear.
• Removing, refer to => [ Removing the 3rd Gear ].
• Installing, refer to => [ Installing the 3rd Gear ].
6 Locking Ring
• Always replace
7 4th Gear
• Removing with the outer race/tapered roller bearing and sleeve, refer to => [ Removing the 4th Gear with the Tapered
Roller Bearing and Sleeve ].
• Installing, refer to => [ Removing the 4th Gear ].
• The shoulder faces 3rd gear.
8 Bearing Inner Race/Taper Roller Bearing
• Removing with the 4th gear and sleeve, refer to => [ Removing the 4th Gear with the Tapered
Roller Bearing and Sleeve ].
• Installing, refer to => [ Installing the Bearing Inner Race/Taper
Roller Bearing ].
9 Thrust Washer
10 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing ].
• Installing, refer to => [ Installing the Outer Race/Tapered Roller
Bearing ].
11 Adjusting Shim
• Determining thickness, refer to => [ Input Shaft, Adjusting ] Input Shaft, Adjusting.
12 Transmission Housing
13 Sleeve
• For the needle bearing,
• Pressing off with the 4th gear drive gear and tapered roller bearing inner race. Refer to => [ Removing the 4th Gear with the Tapered
Roller Bearing and Sleeve ].
• Installing, refer to => [ Installing the Needle Bearing Sleeve ].
• Mount before installing the thrust washer - item 9 -.
14 Needle Bearing
15 5th Gear
16 5th Gear Synchronizer Ring
• With cast locking pieces, refer to => [ 5th Gear Synchronizer Ring with Cast
Locking Pieces ] Transmission.
• Checking for wear, refer to => [ Checking 5th Gear Synchronizer Ring ] Transmission.
17 Spring
• Installed position, refer to => [ Assembling the 5th Gear Locking Collar/Synchronizer
Hub ].
• From transmission build date 05 November 2001, offset springs. Refer to => [ Installation of the Offset Springs ].
18 Locking Pieces
• Quantity: 3
• Installed position, refer to => [ 5th Gear Synchronizing ].
19 5th Gear Synchronizer Hub
• Removing, refer to => [ Transmission ] Transmission.
20 5th Gear Locking Collar
• Remove with the 5th gear synchronizer hub from the => [ Transmission ] Transmission.
21 Plate Spring
• Installed position, refer to => [ Installed Position of the Concave Washers
for the 5th Gear Synchronizing Hub and Gear Bolts ] Transmission.
22 Bolt
• See - item 4 - in => [ Transmission Housing and 5th Gear Cover ] Transmission Component Overviews.
• Always replace
• Holds in position with the adapter on the plate spring bolt head. Refer to => [ Installed Position of the Concave Washers
for the 5th Gear Synchronizing Hub and Gear Bolts ] Transmission.
Removing the Outer Race/Tapered Roller Bearing
Installing the Outer Race/Tapered Roller Bearing
Removing the Bearing Inner Race/Taper Roller Bearing
A Kukko separating tool 12-75 mm (Kukko 17/1)
Installing the Bearing Inner Race/Taper Roller Bearing
Removing the 4th Gear with the Tapered Roller Bearing and Sleeve
Removing the 3rd Gear
Installing the 3rd Gear
Removing the 4th Gear
The shoulder faces the 3rd gear.
Installing the Bearing Inner Race/Taper Roller Bearing
Installing the Needle Bearing Sleeve
Removing the Outer Race/Tapered Roller Bearing
Installing the Outer Race/Tapered Roller Bearing
- Install with a shim after adjusting the input shaft.
5th Gear Synchronizing
1. Springs for the locking pieces
2. Locking collar with 3 notches - arrow A - for the locking pieces - 4 -
3. Synchronizer hub
4. Locking pieces - installed position: the extension - arrow B - faces toward the pointed teeth of the locking collar - item 2 -
Assembling the 5th Gear Locking Collar/Synchronizer Hub
- Slide the locking collar over the synchronizer hub.
The pointed teeth - A - and the shoulder - B - on the synchronizer hub face in the same direction. Recesses for locking pieces in locking collar and synchronizer hub must line up (=> [ 5th Gear Synchronizing ] ).
- Insert locking pieces (Location:=> [ 5th Gear Synchronizing ] ).
- Install the springs offset by 120 degrees under the tabs - C -. The angled end of the spring must be positioned in front of the locking pieces - arrows -.
Installation of the Offset Springs
These springs - A - are installed on both sides.
- Springs are only installed in conjunction with hollow locking pieces.
- Insert locking pieces (Location: => [ 5th Gear Synchronizing ] ).
Spring installed position:
- Install the circlips 120 degrees offset.
- Angled end - A - of spring must engage into the hollow locking piece.
It must be located below the tab - B - of the locking pieces.
The offset end always faces away from the synchronizer hub - direction of arrow -.