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 lock ring.

Removing the Grooved Ball Bearing





- Remove the lock 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 lock 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)

Assembly

Installing 5th Gear





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

Grooved Ball Bearing Installed Position





The groove for the lock 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 lock ring on the input shaft (see the next graphic).

Determining the Grooved Ball Bearing Lock Ring on the Input Shaft





- Insert a 1.86 mm lock 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 lock ring - A - with a feeler gauge - C -.

- Remove the lock ring used for the measurement.

- Select the lock ring according to the table.

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

The following lock rings are available:






Removing the Cylindrical Roller Bearing from the Clutch Housing





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

- Remove the pliers before the cylindrical roller bearing gets into its installed position. The lock 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

There is a washer above and below the grooved ball bearing (- item 6 - in the => [ Input Shaft Overview ] Input Shaft Overview) seat.

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.






Flattened Areas on the Grooved Ball Bearing - A - and Bearing Seat - B - in the Transmission Housing from Approximately Transmission Build Date 21 January 2008





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