Input Shaft

Input Shaft

Special tools, testers and auxiliary items required

• Thrust Plate (VW 401)

• Thrust Plate (VW 402)

• Punch (VW 407)

• Punch (VW 408 A)

• Thrust Disc (VW 412)

• Thrust Tube (VW 454)

• Thrust Tube (VW 455)

• Sleeve (VW 519)

• Press Tube (2040)

• Pressure Washer (3074)

• Kukko Extractor 37-46 mm (21/5)

• Kukko Puller 65-160 mm (18/1)

• Kukko Separating Tool 22-75 mm (17/1)

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

• Kukko Support (22/2)

• Feeler Gauge

Remove the Seal and Remove the Roller Bearing from the Clutch Housing





A Support, for example (22/2)
B Extractor 37-46 mm, for example (21/5)

Pressing the Roller Bearing into the Clutch Housing





- Install the roller bearing seal.

Remove the Roller Bearing Inner Race - D -.





- Clamp the input shaft in a vise. Use jaw protectors - C -.

A Puller, for example (18/1)
B Separating tool 12-75 mm, for example (17/1)

• The roller bearing inner race can also be removed with the 4th gear. Refer to => [ Removing the 4th Gear ].

Removing the 4th Gear





• 4th gear installed position: the high inner collar - arrow - faces the pressing tool.

installing the 4th Gear





Installing the Roller Bearing Inner Race - A -





- Install the locking ring.

Remove the Seal and Remove the Grooved Ball Bearing with the 6th Gear





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

- Remove the locking ring.

Removing the Synchronizer Hub/Locking Collar for 5th and 6th Gear with Selector Gear for 6th Gear





Checking the 5th and 6th Gear Synchronizer Rings for Wear





- Press the synchronizer ring onto the taper of the gear l and measure the gap dimension - a - with a feeler gauge.






Disassembling and Assembling the Locking Collar and Synchronizer Hub for 5th and 6th Gears





1. Spring

2. Locking piece

3. Locking collar

4. Synchronizer hub


- Slide the locking collar over the synchronizer hub.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Assembling the Locking Collar/Synchronizer Hub for 5th and 6th Gears





The locking collar is pushed over the synchronizer hub.

- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Installed Position: Locking Collar/5th and 6th Gear Synchronizer Hub





The high inner collar of the synchronizer hub - arrow - points to 5th gear.

- Install the needle bearing.

- Install the 5th gear and synchronizer ring.

Installing the Locking Collar/Synchronizer Hub for 5th and 6th Gears





- Install the locking ring.

- Install the needle bearing.

- Install the 6th gear and synchronizer ring.

• Grooved ball bearing installed position: the groove for the seal points upward - arrow A - and the shoulder - arrow B - must point to the 6th gear.

Installing the Grooved Ball Bearing