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)
• Install all input shaft bearings using transmission fluid.
• Always replace the grooved ball bearing => [ (Item 6) Grooved Ball Bearing ].
1 Locking Ring
• For the grooved ball bearing/input shaft => [ (Item 6) Grooved Ball Bearing ].
• Removing and installing, refer to => [ Transmission, without a Sealing Cap Circlip ] Transmission, without a Sealing Cap Circlip.
2 Washer
• Outer circumference = 78.6 mm.
• Only insert with the changed transmission housing (from transmission production date 10 April 2006 through approximately 20 January 2008). Refer to => [ Grooved Ball Bearing Changes ].
• Refer to the Parts Catalog.
3 Transmission Housing
• Adapted in the grooved ball bearing seat area => [ (Item 6) Grooved Ball Bearing ] and washers => [ (Item 2) Washer ] and => [ (Item 4) Washer ] from transmission build date 10 April 2006 through approximately 20 January 2008. Refer to => [ Grooved Ball Bearing Changes ].
• Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date 21 January 2008. Refer to => [ Grooved Ball Bearing Changes ].
4 Washer
• Outer circumference = 85 mm.
• Only insert with the changed transmission housing (from transmission production date 10 April 2006 through approximately 20 January 2008). Refer to => [ Grooved Ball Bearing Changes ].
• Refer to the Parts Catalog.
5 Locking Ring
• Select when replacing the grooved ball bearing => [ (Item 6) Grooved Ball Bearing ] and the input shaft => [ (Item 8) Input Shaft ]. Refer to => [ Selecting the Locking Ring ].
6 Grooved Ball Bearing
• Always replace.
• Removing, refer to => [ Removing the Grooved Ball Bearing ].
• Installed position, refer to => [ Grooved Ball Bearing Installed Position ].
• Installing, refer to => [ Installing the Grooved Ball Bearing ].
• Flattened areas on grooved ball bearing and bearing seat approximately from transmission build date 21 January 2008. Refer to => [ Flattened Areas on the Grooved Ball
Bearing and Bearing Seat in the Transmission Housing, Approximately
from Transmission Build Date 21 February 2008 ].
7 5th Gear
• Available as a replacement part together with the input shaft.
• Removing, refer to => [ Removing the 5th Gear ].
• Installed position: the surrounding groove - arrow - points toward the grooved ball bearing => [ (Item 6) Grooved Ball Bearing ].
• Installing, refer to => [ Installing 5th Gear ].
8 Input Shaft
• With the 3rd/4th and 6th gear.
9 Cylindrical Roller Bearing
• With locking ring.
• Removing, refer to => [ Removing the Cylindrical Roller Bearing
from the Clutch Housing ].
• Installing, refer to => [ Pressing Cylindrical Roller Bearing
into the Clutch Housing ].
• Installed position: the circlip in the bearing points to input shaft.
10 Clutch Housing
Disassembling
- Remove the grooved ball bearing locking ring.
Removing the Grooved Ball Bearing
- Mount the thrust pad 16.5/28 mm dia. (VW 431) and the thrust piece (40-105) on the input shaft before mounting 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 12 to 75 mm, for example, kukko separating tool 12-75 mm (17/1)
Removing the 5th Gear
A Separating tool 22 to 115 mm, 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 - on the thrust tube (VW 454) faces the thrust disc (VW 412).
- Select the grooved ball bearing locking ring and install it on the input shaft. Refer to => [ Selecting the Locking Ring ].
Selecting the Locking Ring
- 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 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 ].
Above the Bearing Seat:
Below the Bearing Seat:
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 ].
Flattened Areas on the Grooved Ball Bearing and Bearing Seat in the Transmission Housing, Approximately from Transmission Build Date 21 February 2008
• If the flattened areas - A and B - are present, do not insert any washers above and below the grooved ball bearing.