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 30-37 mm (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





- Remove the locking ring from the input shaft beforehand.

- Install the thrust pad 16.5/28 mm dia. (VW 431) and the thrust piece (40-105) on the input shaft before installing the puller.

- Position the separating tool - B - in the surrounding groove inside the bearing for the locking ring.

A Puller, for example, Kukko puller 65-160 mm (18/1)
B Separating tool, for example, Kukko separating tool 12-75 mm (17/1)

Removing 5th Gear





A Separating tool, for example, Kukko separating tool 22-115 mm (17/2)

Assembling

Installing 5th Gear





The groove - arrow - on the gear must face up.

Grooved Ball Bearing Installed Position





The groove for the locking ring faces up - arrow A - and the collar - arrow B - must face the 5th gear.

Installing the Grooved Ball Bearing





Grooved Ball Bearing with a Rubber Ring - arrow -

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

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

Determining the Grooved Ball Bearing Locking Ring for the Input Shaft





- Insert a 1.86 mm locking ring - A - into the groove in the input shaft and press it upward.

- Measure the gap between the grooved ball bearing - B - and the installed locking ring - A - with a feeler gauge - C -.

- Remove the locking ring used for the measurement.

- Select the locking ring according to the table.

• For the correct locking rings, refer to the Parts Catalog.

The following locking rings are available:






Removing the Cylindrical Roller Bearing from the Clutch Housing





- Compress the cylindrical roller bearing locking ring - arrow - with pliers - C - and remove it.

A Counter support, for example, Kukko support (22/2)
B Internal puller 30 to 37 mm, for example, Kukko extractor 30-37 mm (21/5)

Pressing the Cylindrical Roller Bearing into the Clutch Housing





- Compress the cylindrical roller bearing locking ring - arrow - with pliers - C - and install it.

- Remove the pliers before the cylindrical roller bearing gets into its installed position. The locking ring must lock into the groove on 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 February 2008.





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