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)

• Punch (VW 408 A)

• Thrust Plate (VW 402)

• Tube 28 mm Dia. 100 mm (VW 421)

• Thrust Pad (VW 447 i)

• Thrust Tube (VW 454)

• Thrust Pad (VW 510)

• Mounting Universal Joint (41-501)

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

Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





Removing the Bearing Inner Race/Tapered Roller Bearing





A Separating tool, for example, Kukko separating tool 12-75 mm (17/1)

Installing the Bearing Inner Race/Tapered Roller Bearing





Removing the 4th Gear with the Tapered Roller Bearing and Sleeve





Removing the 3rd Gear





Installing 3rd Gear





Installing 4th Gear





The shoulder faces 3rd gear.

Installing the Bearing Inner Race/Tapered Roller Bearing





Installing the Needle Bearing Sleeve





Removing the Outer Race/Tapered Roller Bearing





Installing the Outer Race/Tapered Roller Bearing





- Install with the shim after adjusting the input shaft.

5th Gear Synchronizer





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 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 the locking pieces in the locking collar and synchronizer hub must line up (refer to => [ 5th Gear Synchronizer ] )

- Insert locking pieces (Location: refer to => [ 5th Gear Synchronizer ] )

- Install the springs offset by 120° 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 - A -





These springs are installed on both sides.

- Springs are only installed in conjunction with hollow locking pieces.

- Insert locking pieces (Location: refer to => [ 5th Gear Synchronizer ] )

Spring Installed Position:






- Install the springs 120° offset.

- Angled end - A - of the 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 in the - direction of the arrow -.